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ISSUED BY RPP-WTP PDC
• RIVER PROTECTION PROJECT - WASTE TREATMENT PLANT
ENGINEERING SPECIFICATION
FOR
DFLA W Effluent Management Facility Atmospheric Process Vessels
Content applicable to ALARA?
ADRNo. 24590-BOF-ADR-M-16-0003
Specification changes retroactive?
[8J Yes O No
Rev 0
[8J Yes O No 0 N/A (alpha revision or revision 0)
Retroactive applicability: All changes in this revision are to be incorporated by the SELLER into equipment design and fabrication for all items on the purchase order.
NOTE: Contents of this document are Dangerous Waste Permit affecting.
3 V"'z/11!, Jung Shin Erica Poberezny NIA
Originator tutlH~
B?~:P~!!~e~rerez V Reviewed By· Jung Shin - jwshin1 No Comments
By: Tracy Ha'Mdns • nthawkin Org Name. Bechtel National. Inc. Org Name Bechtel National, Inc.
Placed· Jan 17. 2018 Org Name: Engineering
Placed: Jan 18. 2018 lf'laced: Jan 22. 2018
2 09101/2017 Jung Shin Erica Poberezny NIA
1 02101/2017 Jung Shin Holden Carroll NIA
24590-G04B-F00009 Rev 20 (Revised 4/1212017)
Quality Level
CM
DOE Contract No. DE-AC27-01RV14136
Youssef Mohammad-Zadeh
l~unkle @ Approved ~ By. Allen Kunkle - ackunkle
Org Name: Bechtel
Placed· Jan 18. 2018
Youssef Mohammad-Zadeh
Allen Kunkle
Youssef Mohammad-Zadeh
Julian Learn
Pagei Ref: 24590-WTP-3DP-G04B-00049
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric Process Vessels
Page ii
24590-G04B-F00009 Rev 20 (4/12/2017) Ref: 24590-WTP-3DP-G04B-00049
0 06/13/2016 Ben Foard Steve Duncan N/A
Youssef Mohammad-
Zadeh
Julian Leam
REV DATE BY CHECK AUTHORIZATION APPROVER *
SPECIFICATION No. 24590-BOF-3PS-MVSC-T0002
Rev 3
*The designated procedure subject matter expert (SME) for 24590-WTP-3DP-G04B-00049, Engineering Specifications, will
concur with the retroactive determination and retroactive applicability details for all Specification Change Notices. Designated
procedure SME Concurrence is documented by the initials of the SME in or by the Approval box. See CCN 263771 for details.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric Process Vessels
Page iii
24590-G04B-F00009 Rev 20 (Revised 4/12/2017) Ref: 24590-WTP-3DP-G04B-00049
Revision History
Q Specification
Revision Only
Margin Reduced? CM
Only
Revision Reason for Revision YES NO N/A
0 Issed for Quote N/A N/A N/A
1 Issued for Purchase. Incorporated Specification Change Notice, 24590-
BOF-3PN-MVSC-00002 to incorporate new supplier quality
requirements. Incorporated EIE, 24590-WTP-EIE-MS-16-0036, which
requires no actions for in-progress procurements. Incorporats EIE,
24590-BOF-EIE-MS-16-0060, which requires no actions. Deleted
Exhibit 8, Pressure Vessels Fatigue Analysis, as project calculation
(24590-BOF-MVC-M80T-00001) indicates a fatigue analysis is not
required. Deleted requirements associated with Low Point Drain Vessels
In-Vessel Pumps (DEP-PMP-00001A/B) and Motors (DEP-MTR-
00001A/B), as the equipment requirements will be captured on a separate
document. Added Section 3.3.2.5 to include requirements to provide
lugs.
2 Issued for Purchase. Deleted Exhibit 9 and replaced it with 24590-WTP-
3PS-MVB2-T0001, Rev. 4, under Section 2.3.1.5 (Sections 5.1.3, 6.3.1,
10.2.7.1, 10.2.8.2, 10.2.8.6, 10.2.8.9, 10.2.8.14 and 10.2.8.15 are
modified to align with the replacement). Added C&I drawings for level
and temperature instruments under Sections 2.3.2.22 and 2.3.2.23.
Removed C&I details that are no longer applicable (Reference 2.3.2.2.,
2.3.2.7, 2.3.2.8, 2.3.2.20, and 2.3.2.21). Modified Section 3.3.2.2 to
reflect the scope and addition of the C&I drawing. Deleted all references
related to DEP-VSL-00004A/B since the equipment is not being
purchased under this order. Added Sections 3.5.4, 3.5.5, 3.5.6, and
Exhibits 12, 13, and 14 to incorporate nozzle loading requirement for the
vessels. Modified Sections 2.2.7 and 3.5.7 to include platforms and
ladders requirements from OSHA 1910 Subpart D, November 18, 2016.
Modified Sections 1.2.1, 1.3.7, 2.2.9, 3.2.8, 3.2.9, and 10.2.3.1 to further
define Supplier's scope associated with insulation bar stock, clips and
support rings that will be welded to the vessels. Other minor
corrections/clarifications have been made. No EIEs against this
document.
3 Issued for incorporation of design change documents. Incorporated the
following SDDRs:
24590-WTP-SDDR-MS-17-00111; Modified Exhibit 6, Sections 3.10.3
and 3.10.4.
24590-WTP-SDDR-MS-17-00117; Modified Exhibit 6, Sections 3.5.3.3,
3.9.1.4, and 3.10.9. Deleted Exhibit 6, Sections 2.2.1.11, 3.9.1, 3.9.3 and
3.9.4.
24590-WTP-SDDR-MS-17-00118; Added Section 1.3.10, Modified
Sections 3.4.2, 4.2.2, 5.1.8, and 10.2.9.4.
Added Section 11 to include all Incorporation by Reference SDDRs.
Please note that source, special nuclear, and byproduct materials, as defined in the Atomic Energy Act of 1954 (AEA) areregulated at the U. S. Department of Energy (DOE) facilities exclusively by DOE acting pursuant to its AEA authority. DOEasserts that pursuant to AEA, it has sole and exclusive responsibility and authority to regulate source, special nuclear, andbyproduct materials at DOE-owned nuclear facilities. Information contained herein on radionuclides is provided for processdescription purposes only.
• • ~
• • ~
• • ~
24590-BOF-3PS-MVSC-T0002, Rev 3
DFLAW Effluent Management Facility Atmospheric Process Vessels
Page iii
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Contents
1 Scope .......................................................................................................................................1
1.1 Project Description and Location ......................................................................................................... 1
1.2 Equipment, Material, and Services Required ...................................................................................... 1
1.3 Work by Others ...................................................................................................................................... 2
1.4 Acronyms and System Designators....................................................................................................... 2
1.5 Safety/Quality Classifications ................................................................................................................ 3
2 Applicable Documents ...........................................................................................................3
2.1 General .................................................................................................................................................... 3
2.2 Codes and Standards ............................................................................................................................. 3
2.3 Reference Documents/Drawings ........................................................................................................... 4
3 Design Requirements .............................................................................................................5
3.1 General .................................................................................................................................................... 5
3.2 Basic Function ........................................................................................................................................ 5
3.3 Performance ........................................................................................................................................... 6
3.4 Design Conditions................................................................................................................................... 8
3.5 Loadings .................................................................................................................................................. 8
3.6 Environmental Conditions .................................................................................................................. 10
3.7 Accessibility and Maintenance ............................................................................................................ 10
4 Materials ...............................................................................................................................10
4.1 General .................................................................................................................................................. 10
4.2 Materials and Equipment .................................................................................................................... 11
4.3 Construction ......................................................................................................................................... 11
4.4 Prohibited Materials ............................................................................................................................ 11
5 Fabrication ...........................................................................................................................11
5.1 General .................................................................................................................................................. 11
6 Tests and Inspections ..........................................................................................................12
6.1 General .................................................................................................................................................. 12
6.2 Shop Tests ............................................................................................................................................. 12
6.3 Non-Destructive Examination ............................................................................................................. 12
6.4 Inspection and Test Status ................................................................................................................... 13
7 Preparation for Shipment ...................................................................................................13
7.1 General Requirements ......................................................................................................................... 13
7.2 Tagging and Marking .......................................................................................................................... 13
24590-BOF-3PS-MVSC-T0002, Rev 3
DFLAW Effluent Management Facility Atmospheric Process Vessels
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24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
8 Quality Assurance ...............................................................................................................14
9 Configuration Management ...............................................................................................14
10 Documentation and Submittals ..........................................................................................14
10.1 General .................................................................................................................................................. 14
10.2 Submittals ............................................................................................................................................. 15
11 Design Changes Incorporated by Reference .....................................................................23
Exhibits
EXHIBIT 1 | Positive Material Identification (PMI)...…………………...…………………………......1-1
EXHIBIT 2 | Structural Design Loads for Seismic Category IV Equipment and Tanks.…………....2-1
.
EXHIBIT 3 | Cold Bending of Pipe ..……………………….……………................................................3-1
EXHIBIT 4 | General Welding and NDE Requirements for Supplier Fabricated Piping...…..……...4-1
EXHIBIT 5 | Shop Fabrication of Piping...…………………………..…………………………..……...5-1
EXHIBIT 6 | Pressure Vessel Design and Fabrication……...……………………………..……….…...6-1
EXHIBIT 7 | Seismic Qualification Criteria for Pressure Vessels..……………………………............7-1
EXHIBIT 8 | Deleted………………………………………………...………………………...…….…….8-1
EXHIBIT 9 | Deleted……………………………………………………………………….….…….…….9-1
EXHIBIT 10 | Technical Supply Conditions for Pipe, Fittings, and Flanges..………....…..…….......10-1
EXHIBIT 11 | Low Voltage Inductions Motors..……………………….………………………..….….11-1
EXHIBIT 12 | Minimum Nozzle Design Loads for DEP-VSL-00001.....……………………….….….12-1
EXHIBIT 13 | Equipment Nozzle Loads (DEP-VSL-00002)….……….……………………….…..….13-1
EXHIBIT 14 | Equipment Nozzle Loads (DEP-VSL-00003A/B/C)…....……………………….….….14-1
24590-BOF-3PS-MVSC-T0002, Rev 3
DFLAW Effluent Management Facility Atmospheric Process Vessels
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24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
1 Scope
1.1 Project Description and Location
The Office of River Protection (ORP) and its contractors manage 177 underground radioactive
waste storage tanks at the Hanford Site in Washington. These tanks contain approximately 56
million US gallons of radioactive waste. Bechtel National, Inc. (BNI) has entered into contract
with the US Department of Energy to design, construct, and commission the Hanford Tank Waste
Treatment and Immobilization Plant (WTP) to process and vitrify this waste into a stable form
that is suitable for permanent storage or disposal. The WTP will be constructed in the 200 East
Area of the Hanford Site, near Richland, Washington. The main facilities within the WTP
complex will be the Pretreatment facility (PTF), Low-Activity Waste facility (LAW), High-Level
Waste facility (HLW), Analytical Laboratory (Lab), Balance of Facilities (BOF) and the Effluent
Management Facility (EMF).
1.2 Equipment, Material, and Services Required
This specification describes the minimum technical requirements for the design, fabrication, and
testing of Quality Level, Commercial Grade (CM) vessels for use in the EMF.
In case of conflict between any requirement specified herein and the requirements of any other
referenced document, the SELLER shall submit Supplier Deviation Disposition Request (SDDR)
for resolution. All deviations considered for incorporation in the work must be submitted to the
BUYER on completed SDDR form for BUYER’s approval.
The scope of work for the SELLER includes, but is not limited to, the following:
1.2.1 Furnish and install vessels and internal/external components in accordance with this
specification. The SELLER shall provide the necessary equipment listed below (as applicable
per associated vessel Mechanical Data Sheet (MDS)) that meets the requirements of this
specification, applicable industry codes, and their design.
a) Vessels
b) Spray nozzle(s)
c) Eductor(s)
d) Vessel internal piping associated with spray nozzles and eductors. Internal piping
includes but is not limited to external nozzle extensions, all pipe inside the vessels, and
associated pipe supports requiring only connecting to BUYER’s pipe system.
e) Deleted
f) Agitators
g) Maintainable vessel components (platform, ladder, vessels, clips for platform, and
pipe/conduit supports, etc.).
h) Insulation clips and supports.
24590-BOF-3PS-MVSC-T0002, Rev 3
DFLAW Effluent Management Facility Atmospheric Process Vessels
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24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
For the purpose of this specification, the vessel internal piping is defined as piping between vessel
internal components (spray nozzles and eductors) and vessel nozzles.
1.2.2 Provide the documents, as submittals, required in this specification and reference
specifications, per the G-321-E, Engineering Document Requirements, and G-321-V, Quality
Verification Document Requirements forms attached to the Material Requisition (MR).
1.2.3 The SELLER may subcontract portions of the work, including any portion of the design,
fabrication, manufacturing, or inspection, provided it meets the conditions of this
specification.
1.3 Work by Others
The following items and services will be supplied by the BUYER and are not included in the SELLER’s
scope of work:
1.3.1 Installation at BUYER’s facility including installation labor and interconnecting piping.
1.3.2 Instrumentation and controls (including installation).
1.3.3 Ring beam support for the vessels.
1.3.4 Vessel vent systems.
1.3.5 Utility (i.e. air, steam, service water, demineralized water and cooling water) supply systems.
1.3.6 Foundation and anchorage.
1.3.7 Thermal insulation; including any materials associated with floating rings, jacketing, banding,
vapor barriers, wire, or fasteners for the thermal insulation.
1.3.8 Electrical power supply
1.3.9 Shipping
1.3.10 Corrosion allowance evaluation for vessel internal components (e.g. eductor, spray nozzle,
agitator, etc.)
1.4 Acronyms and System Designators
1.4.1 Acronyms
AISC American Institute of Steel Construction
ASME American Society of Mechanical Engineers
CM Commercial Grade
DFLAW Direct Feed Low-Activity Waste
EMF Effluent Management Facility
MDS Mechanical Data Sheet
MTR Material Test Report
MR Material Requisition
NDE Non-Destructive Examination
24590-BOF-3PS-MVSC-T0002, Rev 3
DFLAW Effluent Management Facility Atmospheric Process Vessels
Page 3
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
NTE Not-to-Exceed
PMI Positive Material Identification
QAP Quality Assurance Program
SC Seismic Category
SDDR Supplier Deviation Disposition Request
WTP Hanford Tank Waste Treatment and Immobilization Plant
1.5 Safety/Quality Classifications
1.5.1 The components specified in this specification do not perform a safety function and are
therefore identified with a “Commercial Grade (CM)” classification.
1.5.2 The vessels shall be designed as Seismic Category IV (SC-IV).
2 Applicable Documents
2.1 General
2.1.1 When specific chapters, sections, parts, or paragraphs are listed following a code, industry
standard, or reference document, only those chapters, sections, parts, or paragraphs of the
document are applicable and shall be applied.
2.1.2 For the codes and standards listed in Section 2.2, the specific edition year identified shall be
followed. For the codes and standards that are incorporated by reference (daughter codes and
standards), the referenced daughter edition or current edition shall be followed. If an edition
year is not identified, the latest issue, including addenda, at the time of award shall apply.
2.1.3 The edition year listed in Section 2.2 shall apply to, and govern in case of conflict with,
subsequent references to the codes and standards within the referenced documents in section
2.3 and exhibits.
2.1.4 In case of conflict between this specification and referenced codes and standards, the
requirements for all must be met with the most stringent governing.
2.2 Codes and Standards
2.2.1 ASME B31.3, Process Piping
2.2.2 ASME B46.1, Surface Texture (Surface Roughness, Waviness and Lay)
2.2.3 ASME Boiler and Pressure Vessel Code, Section II: Materials
2.2.4 ASME Boiler and Pressure Vessel Code, Section VIII, Div. 1: Rules for Construction of
Pressure Vessels
2.2.5 ASME Y14.100, Engineering Drawing Practices
2.2.6 HIS, Hydraulic Institute Standards
2.2.7 OSHA 1910, Occupational Safety and Health Standards (Subpart D, November 18, 2016)
24590-BOF-3PS-MVSC-T0002, Rev 3
DFLAW Effluent Management Facility Atmospheric Process Vessels
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24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
2.2.8 UBC 1997, Uniform Building Code
2.2.9 PIP INIC1000, Cold Insulation Installation Details
2.3 Reference Documents/Drawings
2.3.1 Reference Documents
2.3.1.1 24590-WTP-3PS-G000-T0003, Engineering Specification for Packaging, Handling, and
Storage Requirements
2.3.1.2 24590-WTP-3PS-G000-T0014, Engineering Specification for Supplier Design Analysis
2.3.1.3 24590-WTP-LIST-ESH-16-0001, Restricted Materials List
2.3.1.4 24590-WTP-DC-ST-01-001, Structural Design Criteria
2.3.1.5 24590-WTP-3PS-MVB2-T0001, Engineering Specification for Welding of Pressure
Vessels, Heat Exchangers and Boilers*
*Any reference to 24590-WTP-3PS-MV00-T0001 in this document should be replaced with Exhibit
6.
2.3.2 Reference Drawings
2.3.2.1 24590-WTP-MV-M59T-00001, Pressure Vessel Tolerances Standard Details
2.3.2.1.1 24590-WTP-MVN-M59T-00036, Tolerance Changes for Weld-Connection Type
Nozzles
2.3.2.1.2 24590-WTP-MVN-M59T-00038, Revised Standard Pressure Vessel Tolerances in Note
A of Drawing
2.3.2.2 Deleted
2.3.2.3 24590-WTP-MV-M59T-00009, Lifting Lugs Standard Details
2.3.2.4 24590-WTP-MV-M59T-00010, Tailing Lug Standard Details
2.3.2.5 24590-WTP-MV-M59T-00012, Grounding Lug Standard Details
2.3.2.6 24590-WTP-MV-M59T-00016001, Vessel Connections Standard Details Sheet 1 of 3
2.3.2.7 Deleted
2.3.2.8 Deleted
2.3.2.9 24590-WTP-MV-M59T-00017, Vessel Inspection Manway Standard Details
2.3.2.10 24590-WTP-MV-M59T-00018., Vessel Name Plate Standard Details
2.3.2.11 24590-WTP-MV-M59T-00026, Anchor Bolt Chair Details for Vertical Vessels
2.3.2.11.1 24590-WTP-MVN-M59T-00035, Add Notes for Weld Size Tolerance and Three Sided
Weld as Necessary Between the Plate Washer and Anchor Chair. Add Additional Weld
Symbol Between the Plate Washers and the Top of the Anchor Chairs
2.3.2.12 24590-WTP-PW-P30T-00001, WTP End Prep Detail for Field Butt Welds
24590-BOF-3PS-MVSC-T0002, Rev 3
DFLAW Effluent Management Facility Atmospheric Process Vessels
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2.3.2.13 24590-BOF-DD-25-00004, Effluent Management Facility Vessel Support Ring Beam
Details
2.3.2.14 24590-BOF-DD-25-00012, Effluent Management Facility Concrete Embedment Details
Vessel Support Ring Beam Installation
2.3.2.15 24590-BOF-MV-DEP-00001001, Equipment Assembly Low Point Drain Vessel DEP-
VSL-00001
2.3.2.16 24590-BOF-MV-DEP-00002001, Equipment Assembly Evaporator Feed Vessel DEP-VSL-
00002
2.3.2.17 24590-BOF-MV-DEP-00003001, Equipment Assembly Evaporator Concentrate Vessel
DEP-VSL-00003A
2.3.2.18 24590-BOF-MV-DEP-00004001, Equipment Assembly Evaporator Concentrate Vessel
DEP-VSL-00003B
2.3.2.19 24590-BOF-MV-DEP-00005001, Equipment Assembly Evaporator Concentrate Vessel
DEP-VSL-00003C
2.3.2.20 Deleted
2.3.2.21 Deleted
2.3.2.22 24590-WTP-MV-M59T-00036, Control and Instrumentation Process Vessel Stilling Well
Welded Assembly for Level Instruments
2.3.2.23 24590-WTP-MV-M59T-00040, Control and Instrumentation Process Vessel Thermowell
Welded Assembly for Temperature Instruments
3 Design Requirements
3.1 General
The SELLER shall comply with Sections 1.2 and 3 of Exhibit 6, Pressure Vessel Design and Fabrication.
3.2 Basic Function
3.2.1 Unless otherwise specified, equipment shall be designed and fabricated in accordance with the
drawings, design standards identified in the Mechanical Data Sheet (MDS), and any additional
requirements of this specification. Any difference between SELLER’s final design and
BUYER’s data specified in the MDS shall be identified to the BUYER for resolution.
3.2.2 Vessels shall be constructed to ASME Section VIII, Div. 1 requirements and shall have an
ASME code stamp and National Board Registration.
3.2.3 Spray nozzle requirements, for washing of the interior walls of the vessel, shall be provided as
indicated on the vessel MDS.
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DFLAW Effluent Management Facility Atmospheric Process Vessels
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3.2.4 The BUYER will decontaminate the inside of the vessels with demineralized water and 0.5 M
nitric acid using spray nozzles and flushing. The Seller shall design the vessels so as to
maintain functionality without chemical or mechanical degradation of the electrical,
mechanical, or any other components involved.
3.2.5 Eductors requirements, for mixing contents inside of the vessel, shall be provided as indicated
on the vessel and eductor MDS.
3.2.6 Vessel internal piping shall be free-draining and have no traps or pockets that can accumulate
liquids or solids.
3.2.7 All removable vessel internals shall be fabricated for installation and removal through the
specified nozzles on the drawings.
3.2.8 The vessels insulation thickness and density, as specified on the MDS, shall be considered in
determining nozzle projection.
3.2.9 The SELLER shall provide bar stock, clips and support rings, which are welded to the vessel,
to support BUYER insulation in accordance with PIP INIC1000, Cold Insulation Installation
Details and the requirements as follows;
Intermediate insulation support rings shall be installed every 6’ and be welded to the
vessel (applicable to vessel shell).
The standoff distance for the rings shall match the insulation thickness called out on
the MDS for that vessel (applicable to bottom vessel head and shell).
Support rings shall extend 2” from vessel skirt. Bottom supports shall extend 2”
minimum from vessel skirt (applicable to vessel skirt).
Vessels insulation thickness and density, as specified on the MDS.
3.2.10 All engineering analyses and calculations provided as supplier submittals shall be in
accordance with 24590-WTP-3PS-G000-T0014, Engineering Specification for Supplier
Design Analysis.
3.2.11 Deleted.
3.2.12 SELLER shall provide agitators when specified for a vessel on the vessel MDS. The SELLER
shall determine the design and configuration of the agitator(s) based on the agitator MDS
listed on the vessel MDS.
3.3 Performance
3.3.1 General
3.3.1.1 The performance characteristics of equipment shall be in accordance with the MDS.
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3.3.1.2 Unless otherwise specified in the MDS, the SELLER shall propose its recommendation for
equipment for BUYER review and approval prior to fabrication and/or incorporation into
the design of the equipment.
3.3.1.3 The SELLER shall provide completed MDS for each equipment as indicated by the
BUYER.
3.3.2 Vessels
3.3.2.1 The vessel skirt support shall be designed to support BUYER-specified ring beam design as
provided on the BUYER’s drawings (References 2.3.2.13 and 2.3.2.14).
3.3.2.2 Vessels shall incorporate nozzle connections for temperature and level instrumentation
(including standpipes) as provided on the BUYER’s drawings (References 2.3.2.22 and
2.3.2.23).
3.3.2.3 Deleted.
3.3.2.4 SELLER shall provide a recommended list and number of spare parts for BUYER’s review.
3.3.2.5 SELLER shall provide lugs (tailing, lifting, and grounding lugs) in accordance with
BUYER’s drawings (Reference 2.3.2.3, 2.3.2.4, and 2.3.2.5).
3.3.3 Eductors
3.3.3.1 At a minimum, SELLER shall provide the following eductor performance characteristics
based on information specified in the MDS.
a) Number of eductors
b) Location and orientation of eductors
c) Vessel internal piping layout
d) Flow rates (Inlet and Outlet)
e) Pressure drop
f) Minimum mixing time
g) Suction pickup ratio (the ratio of entrained flow to motive flow)
3.3.3.2 Overall vessel batch mixing will be required to provide turbulence at the bottom of the
vessel in order to prevent the build-up of solids on the bottom of the vessel.
3.3.3.3 Mixing at the low level in vessels should not cause any splashing or spraying of process
fluid in order to avoid the possibility of airborne radioactive particles being formed.
3.3.4 Spray Nozzles
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DFLAW Effluent Management Facility Atmospheric Process Vessels
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3.3.4.1 At a minimum, SELLER shall provide the following spray nozzle performance
characteristics based on information specified in the MDS.
a) Number of spray nozzles
b) Performance curve (Flow vs. Pressure)
c) Operating range (Flow, Pressure, and Temperature)
3.3.5 Deleted
3.3.6 Low Voltage Induction Agitator Motor
3.3.6.1 Electrical Requirements
Agitator motor(s) shall be compliant with Exhibit 11, Low Voltage Induction Motors.
3.3.7 Agitators
When agitators are specified for a vessel on the MDS, the SELLER shall determine the design
and configuration of the agitator(s) based on the agitator MDS listed on the vessel MDS. This
includes minimum mixing time as specified on the MDS.
3.4 Design Conditions
3.4.1 All vessels and associated equipment covered by this specification shall be designed for a
minimum design life of 40 years, unless otherwise noted, inclusive of maintenance. Design
life of equipment shall consider the effects of chemical, radiological, and thermal exposure.
3.4.2 Deleted.
3.4.3 SELLER shall conform to BUYER’s requirements for layout, and dimensions as shown in the
drawings (Reference 2.3.2.15 through 2.3.2.19) and the not-to-exceed (NTE) dimensions on
the MDS.
3.5 Loadings
3.5.1 Loads to be considered for the structural design of vessels, including vessel skirt support, and
associated internal /external components shall be in accordance with applicable codes,
standards, and reference documents listed in Section 2 of this specification.
3.5.2 SELLER shall include the location of the anchorage in relation to the vessel skirt support in
relation to the vessel outline drawings supplied to the BUYER. In addition to location, the
SELLER shall provide the BUYER maximum anchorage loads for all load cases (including
seismic).
3.5.3 SELLER shall complete a seismic analysis of the vessels and vessel components, including
support skirt, welded anchor points, eductors, internal piping, and maintainable vessel
components.
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Seismic load capability requirements of the vessel components shall be calculated in
accordance with Exhibit 2, Structural Design Loads for Seismic Category IV Equipment and
Tanks.
Vessel seismic analysis shall be performed per the requirements of Exhibits 6, Pressure
Vessels Design and Fabrications, Section 3.2 and Exhibit 7, Seismic Qualification Criteria for
Pressure Vessels.
3.5.4 For DEP Low Point Drain Vessel, SELLER shall comply with nozzle loading requirements in
Exhibit 12, Minimum Design Loads for DEP-VSL-00001, in conjunction with Exhibit 6,
Pressure Vessel Design and Fabrication, Appendix A, Page A-1, in lieu of the nozzle loading
requirements in Exhibit 6, Pressure Vessel Design and Fabrication, Appendix A, Table A2.
This requirement does not apply to manway (N06, Reference 2.3.2.15). Temperature and level
instrument nozzles shall be reduced as follows;
N11 and N15 (Reference 2.3.2.15) for the DEP Low Point Drain Vessel, the Weight
Loads and Seismic Loads in this table shall be divided by 2 and the Thermal Loads
shall be reduced to zero.
3.5.5 For DEP Evaporator Feed Vessel and DEP Evaporator Concentrate Vessels, SELLER shall
comply with nozzle loading requirements in Exhibit 6, Pressure Vessel Design and
Fabrication, Appendix A, Table A2. This requirement does not apply to Manways (N02,
Reference 2.3.2.16 and N01, Reference 2.3.2.17 through 2.3.2.19). Level instrument nozzles
shall be reduced as follows:
N06 (Reference 2.3.2.16), for the DEP Evaporator Feed Vessel the Weight Loads and
Seismic Loads in this table shall be divided by 2 and the Thermal Loads shall be
reduced to zero.
N07, N10, and N15 (Reference 2.3.2.16), for the DEP Evaporator Feed Vessel shall
comply with nozzle loading requirements in Exhibit 13, Equipment Nozzle Loads
(DEP-VSL-00002), in conjunction with Exhibit 6, Pressure Vessel Design and
Fabrication, Appendix A, Page A-1, in lieu of the nozzle loading requirements in
Exhibit 6, Pressure Vessel Design and Fabrication, Appendix A, Table A2.
N03 (Reference 2.3.2.17 through 2.3.2.19), for the Evaporator Concentrate Vessels,
the Weight Loads and Seismic Loads in this table shall be divided by 2 and the
Thermal Loads shall be reduced to zero.
N05, N08, N09 (Reference 2.3.2.17 through 2.3.2.19), for the DEP Evaporator
Concentrate Vessels shall comply with nozzle loading requirements in Exhibit 14,
Equipment Nozzle Loads (DEP-VSL-00003A/B/C), in conjunction with Exhibit 6,
Pressure Vessel Design and Fabrication, Appendix A, Page A-1, in lieu of the nozzle
loading requirements in Exhibit 6, Pressure Vessel Design and Fabrication, Appendix
A, Table A2.
3.5.6 The nozzle size and schedule listed in the BUYER’s drawings (Reference 2.3.2.15 through
2.3.2.19) shall be considered a minimum. The SELLER shall ensure the nozzle end
connection matches the connecting pipe size and schedule as listed in Reference 2.3.2.15
through 2.3.2.19 without affecting the “Z” dimension.
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3.5.7 Platforms, ladders, and handrails are to be designed per OSHA 1910. Fixed ladders and
platforms supplied with the vessels shall meet 29 CFR 1910 Subpart D requirements as
revised by the Occupational Safety and Health Administration (OSHA) on November 18th,
2016. Loads for platform/stairs/handrails are to be in accordance with Section 4.4.1 of
Reference 2.3.1.4 as listed below:
100 psf for minimum uniform load for stairs and platforms.
For handrails, according to UBC 1997, Table 16B.
3.5.8 Weld pads may be required. They should be designed using 25 psf for minimum allowance
for dead loads due to piping, raceway, and other permanent static loads in accordance with
Section 4.3 of Reference 2.3.1.4.
3.6 Environmental Conditions
3.6.1 Vessels shall be designed, equipped, and furnished to be fully operational throughout the
entire range between, and including the limits of, the minimum and maximum conditions
specified on the MDS.
3.6.2 Equipment target radiation level and average contact dose rate are as specified on the MDS.
3.6.3 Equipment shall be designed to comply with an average sound pressure level of 85 dBA at 3
feet from the outline of the equipment, when measured 5 feet above grade/floor or personnel
platform level and under free field conditions. SELLER shall provide how the specified sound
level will be met.
3.7 Accessibility and Maintenance
3.7.1 The design of the vessels shall support the ability to replace maintainable components
(ladders, platforms, vessel clips for conduit supports, etc.) as shown on BUYER drawings.
3.7.2 SELLER shall design the vessel skirt support to provide means of gaining access for
installation, maintenance, removal, and welding activities.
3.7.3 Vessel internal components are not intended to require routine maintenance. SELLER shall
provide recommendations for methods for recovery of blocked vessel internal components
(eductors, piping, agitators, and spray nozzle) in the SELLER submitted operation and
maintenance manuals.
4 Materials
4.1 General
The SELLER shall comply with all requirements of Section 4 of Exhibit 6, Pressure Vessel Design and
Fabrication.
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4.2 Materials and Equipment
4.2.1 Provide equipment and components with the materials of construction as specified per this
specification and on the listed data sheets in Part 2 of the MR. Where specific criteria are not
provided, material selection shall be determined by the SELLER and have properties and
composition suitable for the specific service conditions and consistent with this specification
and its addenda.
4.2.2 Corrosion and erosion allowance is specified on the MDS and shall be applied to each surface
exposed to process liquid.
4.2.3 The SELLER shall not substitute materials without written approval, via the SDDR, from the
BUYER.
4.2.4 SELLER shall comply with the requirements in Exhibit 1, Positive Material Identification
(PMI).
4.3 Construction
4.3.1 For vessels, classification of fabrication materials for bolts and nuts shall be in accordance
with ASME Boiler and Pressure Vessel Code, Section II.
4.3.2 All piping, flanges, and pipe fittings shall comply with the requirements specified in Exhibit
10, Technical Supply Conditions for Pipe, Fittings, and Flanges.
4.4 Prohibited Materials
4.4.1 The materials listed in 24590-WTP-LIST-ESH-16-0001, Restricted Materials List shall not be
used on any supplied equipment and shall not be brought onto WTP site.
4.4.2 Bronze, copper, lead, zinc, tin, antimony, cadmium, their alloys or materials containing such
metals as their basic constituents, or molybdenum and halogens, shall not be used in direct
contact with stainless steel.
4.4.3 For cold bending of pipe, materials for use in contact with stainless steel, SELLER shall
comply with Section 9 of Exhibit 3, Cold Bending of Pipe.
5 Fabrication
5.1 General
5.1.1 The SELLER shall comply with requirements of Sections 5 and 6 of Exhibit 6, Pressure
Vessel Design and Fabrication.
5.1.2 The SELLER shall fabricate vessels and associated components, in accordance with the
BUYER standard details listed under section 2.3.2.
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5.1.3 Design of vessel skirt support shall be in accordance with Exhibit 6, Pressure Vessel Design
and Fabrication, Section 3.10 and 24590-WTP-3PS-MVB2-T0001, Engineering Specification
for Welding of Pressure Vessels, Heat Exchangers and Boilers.
5.1.4 Fabrication of vessel skirt support shall be performed in accordance with Exhibit 6, Pressure
Vessel Design and Fabrication.
5.1.5 All fabrication shall be performed by personnel qualified in accordance with this specification
and applicable documents referenced in Section 2 and exhibits of this specification.
5.1.6 For the equipment supplied per this specification, the SELLER shall ensure that all sharp
edges are broken/smoothed and all burrs removed. Machined metal surfaces subjected to
human touch through maintenance or operational reason shall be constructed to have no sharp
edges unless it serves the function of the equipment.
5.1.7 Machined exposed metal surfaces shall have a surface finish of 125 microinches per ASME
B46.1, Surface Texture (Surface Roughness, Waviness and Lay), or better.
5.1.8 Eductors connections in the piping system shall be threaded with Loctite 2432 (or equivalent).
6 Tests and Inspections
6.1 General
6.1.1 The SELLER shall comply with all requirements of Section 7 of Exhibit 6, Pressure Vessel
Design and Fabrication and Section 3.2 of Exhibit 5, Shop Fabrication of Piping.
6.1.2 The SELLER shall submit original set of radiographic film with associated technique and
reader sheets in accordance with Section 7.2 of Exhibit 6, Pressure Vessel Design and
Fabrication. In addition, the SELLER shall submit original set of vessel assembly seam weld
radiographic film. Film shall be packaged to preclude moisture and handling damage.
6.2 Shop Tests
6.2.1 All pipework shall be hydrostatically tested in accordance with ASME B31.3.
6.2.2 SELLER shall furnish blind flanges or other acceptable closures for the nozzles, as required
for hydrotesting. Closures shall be removed after testing, unless they are required for
shipment.
6.2.3 All test results shall be documented, certified, and submitted to the BUYER for review, in
accordance with G-321-V, Quality Verification Document Requirements forms attached to the
MR.
6.2.4 Vessel maintainable components (ladders, platform, vessel clips for conduit supports, etc.)
shall be tested to the same criteria as the parent tank.
6.3 Non-Destructive Examination
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6.3.1 All pressure vessels shall meet the requirements for welding and non-destructive examination
(NDE) from the following specifications:
a) Exhibit 6, Pressure Vessel Design and Fabrication, Sections 5.4 and 6.
b) 24590-WTP-3PS-MVB2-T0001, Engineering Specification for Welding of Pressure
Vessels, Heat Exchangers, and Boilers.
6.3.2 All pipework shall meet the requirements for welding and NDE from the following
specifications:
a) Exhibit 4, General Welding and NDE Requirements for Supplier Fabricated Piping.
b) Exhibit 5, Shop Fabrication of Piping, Section 3.2.
c) Deleted.
6.4 Inspection and Test Status
6.4.1 The SELLER shall maintain a system for identifying inspection and testing status of items and
systems.
7 Preparation for Shipment
7.1 General Requirements
7.1.1 The SELLER shall comply with all requirements of Section 8 of Exhibit 6, Pressure Vessel
Design and Fabrication.
7.1.2 The vessels shall be packaged, prepared for shipment, handled, and stored in accordance with
24590-WTP-3PS-G000-T0003, Engineering Specification for Packaging, Handling, and
Storage Requirements; excluding any NQA-1 requirements.
7.1.3 All equipment shall be thoroughly cleaned of all debris, trash, weld splatter, loose mill scale,
tools and foreign matter and dried in preparation for shipment.
7.2 Tagging and Marking
7.2.1 Tagging equipment shall be per this specification and the applicable documents listed in
Section 2 and Exhibits of this specification. Plant item numbers shall be per the MDS. In
case of conflict, SELLER shall submit a report identifying any deviations and/or conflicts on
an SDDR form, attached to the MR
7.2.2 Slinging points and orientation for storage shall be clearly marked.
7.2.3 A stainless steel nameplate shall be rigidly attached to the vessels in a prominent position for
ease of visibility, unless a location is indicated on the drawings. The nameplate physical
location shall be visible after insulation is installed. Nameplates shall include the following,
in addition to all markings mandated by the vessel design standard at a minimum:
a) Manufacturer’s name
b) Shop location
c) Date of manufacture
d) Serial number
e) Equipment name and tag number
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f) Weight of assembly
g) Purchase order number
8 Quality Assurance
The SELLER’s manufacturing Quality Assurance Program (QAP) applicable to production of
standard product offerings is acceptable to meet the requirements of this procurement.
9 Configuration Management
Equipment and/or components covered by this specification are identified with Plant Item Numbers
shown in the listed MDS in Part 2 of the MR. Each item shall be identified in accordance with
Section 7.2 of this specification. Configuration Management is maintained by conformance to
approved drawings and procedures.
10 Documentation and Submittals
10.1 General
10.1.1 The SELLER shall comply with all requirements of Section 9 of Exhibit 6, Pressure Vessel
Design and Fabrication.
10.1.2 SELLER shall submit to BUYER all detailed designs, drawings, documentation, procedures,
instructions, calculations, analyses, manufacturer documentation, manufacturer data,
inspection reports, test reports, certificates, and manuals required per this specification, the
applicable codes, standards, and reference documents in Section 2 of this specification, and
the MR.
10.1.3 Documentation shall be submitted to BUYER as summarized on the G-321-E, Engineering
Document Requirements, and G-321-V, Quality Verification Document Requirements forms
attached to the MR.
10.1.4 Interim reviews shall be presented by the SELLER upon reaching or completing specific
milestones as indicated in the “Remarks” column on the G-321-E, Engineering Document
Requirements, and G-321-V, Quality Verification Document Requirements forms attached to
the MR. Interim review discussions are intended to help clarify interface points in system
requirements, review design and design progress, and resolve outstanding issues.
The SELLER is encouraged to provide to the BUYER copies of documentation or information
that is expected to be discussed and presented at the design review prior to the scheduled
meeting. The SELLER shall participate in the design review and present the design, including
discussion of provided submittals. Following the review meeting, the BUYER will formally
transmit to the SELLER any comments or other requests on the appropriate design
documentation. The SELLER is required to provide a response/resolution to the BUYER’s
comments. The SELLER shall be responsible for producing and submitting meeting minutes,
as a formal document of record. The meeting minutes shall include, at a minimum, a list of
actions, actionees, and a documented record of agreed comments from the meeting.
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The first interim review (30%) commences when calculations, drawings, and other applicable
submittal documents. are completed. The second interim review (60%) will be held during the
fabrication stage. The final interim review (90%) will start once fabrication is completed and
prior to shipment. All reviews will be conducted at the Seller’s facility.
10.1.5 Each document to be submitted shall be listed on the 15EX form. This form tracks the
scheduled and actual delivery of each submittal. The form shall be submitted per the G-321-
E.
10.1.6 Deleted.
10.1.7 All drawings shall be produced per the drawing practices set forth in ASME Y14.100,
Engineering Drawing Practices.
10.2 Submittals
10.2.1 Schedule and Drawing Index
SELLER shall develop, and deliver to the BUYER, a schedule detailing the chronological
sequence of activities required to meet the equipment delivery date. At a minimum, the
schedule shall cover equipment design, procurement, fabrication and manufacture, tests and
inspections, verifications and hold points, and production deliverables. In addition, a drawing
index shall be submitted at this time.
10.2.2 Data Sheets
10.2.2.1 Mechanical Data Sheets
SELLER shall provide completed Mechanical Data Sheets as listed in Part 2 of the MR.
10.2.2.2 Motor Data Sheets
SELLER shall provide completed motor data sheets in accordance with Exhibit 11, Low
Voltage Induction Motors, Section 9.1.1(a).
10.2.3 Drawings
10.2.3.1 Outline Drawings
SELLER shall provide drawings with outline dimensions, services, foundations, and
mounting details. Drawings shall show external envelope, including lugs, and centerline(s),
fluid, other service connections, isometrics, insulation clips and supports, and details related
to vessel skirt support. SELLER shall provide support requirements for the vessels (e.g.
vessel skirt access points) to support BUYER’s ring beam design. Outline drawings are to
include the vessel as well as internal components with internal piping.
In addition, shop detail drawings shall meet the requirements from the following:
A) Exhibit 5, Shop Fabrication of Piping, Sections 1.9.2.2 and 1.9.3.1.
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B) Exhibit 6, Pressure Vessel Design and Fabrication, Section 9.6.
C) Section 3.5.2 of this specification
10.2.3.2 Motor Drawings
10.2.3.2.1 Outline Drawings
SELLER shall provide outline drawings to meet the requirements of Exhibit 11, Low
Voltage Induction Motors, Section 9.1.1(b).
10.2.3.2.2 Assembly Drawings
SELLER shall provide assembly drawings per Exhibit 11, Low Voltage Induction
Motors, Section 9.1.1(i).
10.2.3.2.3 Electrical Drawings, Schematics, and Wiring Drawings
SELLER shall provide single line diagrams, schematic diagrams, equipment internal
wiring diagrams, and interconnection wiring diagrams for electrical items in accordance
with Exhibit 11, Low Voltage Induction Motors, Section 9.1.1(c).
10.2.3.3 Shop Detail Drawings and Bill of Materials
SELLER shall provide shop detail drawings with sufficient detail to facilitate fabrication,
manufacture, or installation. This includes a complete Bill of Materials (BOM), pipe spool
drawings, internal piping, cross-section details, and structural details.
In addition, shop detail drawings shall meet the requirements from the following:
a) Deleted.
b) Exhibit 5, Shop Fabrication of Piping, Sections 1.9.2.2 and 1.9.3.1.
c) Exhibit 6, Pressure Vessel Design and Fabrication, Section 9.6.
10.2.3.4 Vessel Nozzle Locations and Connection Details
SELLER shall provide vessel nozzle locations and connection details to interface with
BUYER-supplied piping.
10.2.4 Lists
10.2.4.1 Material List
SELLER shall provide a material list with specific model number, manufacturer, and
catalog cut sheets for all equipment.
10.2.4.2 Recommended Spare Parts List
SELLER shall provide a list of recommended spare parts and supplies for maintainable
vessel components required for maintenance and repair to ensure continued service or
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operation without unreasonable delays, including the cost of each item. The SELLER shall
provide a list of startup and commissioning spares, including all components or equipment
that may be needed during startup and commissioning.
10.2.4.3 Nameplate Engraving List
SELLER shall provide a nameplate engraving list and drawing for all nameplates.
10.2.4.4 Motor Lists
10.2.4.4.1 Recommended Spare Parts List
SELLER shall provide a list of recommended spare parts and supplies required for
maintenance and repair to ensure continued service or operation without unreasonable
delays, including the cost of each item in accordance with Exhibit 11, Low Voltage
Induction Motors, Section 9.1.1(g).
10.2.4.4.2 Motor Data (Lubricants, Gaskets, and Seals)
SELLER shall provide information about lubricants, gaskets and seals in accordance with
Exhibit 11, Low Voltage Induction Motors, Section 9.1.1(k) and (l).
10.2.5 Product Data
10.2.5.1 Inspections and Test Plans
SELLER shall provide a detailed description of their work inspections and tests planned
during the receipt of materials, manufacturing, testing, and conformance verification
activities. SELLER shall include identification of witness and hold points. In addition,
SELLER shall provide inspection and test plans in accordance with Exhibit 6, Pressure
Vessel Design and Fabrication, Section 9.7.
10.2.5.2 Structural Support Requirements
SELLER shall provide structural support data and drawings with recommended support
locations for vessels (i.e., load points, weight distribution, and maximum weight, geometry
of equipment, and location of center gravity).
10.2.5.3 Transportation and Shipping Documentation
SELLER shall provide drawings and a proposed tie down plan for applicable items in
accordance with 24590-WTP-3PS-G000-T0003, Engineering Specification for Packaging,
Handling, and Storage Requirements, Section 11.2.
10.2.5.4 Spray Nozzle Performance Curves
SELLER shall provide spray nozzle performance curves.
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10.2.6 Manuals
10.2.6.1 Installation Instruction Manual
SELLER shall submit an Installation Instruction Manual with drawings and procedures
required for safe assembly and installation of material, including any explanations for
special tools in accordance with 24590-WTP-3PS-G000-T0003, Engineering Specification
for Packaging, Handling, and Storage Requirements, Section 11.1.1.
10.2.6.2 Operation and Maintenance Manuals and Instructions
SELLER shall submit manuals with detailed instructions relating to operation of all
components such as eductors and agitators.
SELLER shall submit maintenance manuals with detailed written instructions to
disassemble, reassemble, and maintain components. Manuals shall include specific
instructions, procedures, and illustrations for preventative and corrective maintenance.
Provide a list of special tools required for maintenance and repair of components.
Corrective maintenance manuals shall include the manufacturer’s procedures and
instructions for correcting problems and making repairs. Provide a troubleshooting guide
and diagnostic techniques, maintenance and repair procedures, removal and replacement
instructions for components, identification of all parts of end items subject to replacement
(including special hardware requirements), warranty information, and personnel training
requirements for operating and maintaining equipment.
10.2.6.3 Site Storage, Handling, and Maintenance Requirements Manual
SELLER shall submit a Site Storage, Handling, and Maintenance Requirements Manual
with procedures and instructions for site storage, handling, and maintenance that will
preserve equipment until it is put into operation in accordance with 24590-WTP-3PS-G000-
T0003, Engineering Specification for Packaging, Handling, and Storage Requirements,
Section 11.1.2.
10.2.7 Procedures
10.2.7.1 Welding and Non-Destructive Examination Procedures and Qualifications
SELLER shall provide welding, weld inspection, NDE, and weld repair procedures and
personnel qualifications in accordance with the following:
a) 24590-WTP-3PS-MVB2-T0001, Engineering Specification for Welding of Pressure
Vessels, Heat Exchangers, and Boilers, Section 4.
b) Exhibit 6, Pressure Vessel Design and Fabrication, Sections 5.4 and 7.2.
c) Exhibit 4, General Welding and NDE Requirements for Supplier Fabricated Piping,
Sections 4 and 13.3.
d) Exhibit 5, Shop Fabrication of Piping, Sections 1.9.2.4 and 1.9.2.5.
e) Deleted.
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10.2.7.2 Material Control Procedures
SELLER shall provide material control procedures including controlling issuance, handling,
storage, and traceability of materials such as weld rod.
10.2.7.3 Cleaning Procedures and Qualifications
Include procedure for descaling after hot working or heat treatment per Exhibit 6, Pressure
Vessel Design and Fabrication, Section 8.1.2.
In addition, SELLER shall provide cleaning procedures per Exhibit 5, Shop Fabrication of
Piping, Section 1.9.2.7.
10.2.7.4 Positive Material Identification Procedures
SELLER shall submit procedures covering how PMI will be conducted and documented per
Exhibit 1, Positive Material Identification (PMI), Section 3.2.
10.2.7.5 Pipe Bending Procedures
SELLER shall submit pipe bending procedures and bend qualification records per Exhibit 6,
Pressure Vessel Design and Fabrication, Section 5.1.10, Exhibit 5, Shop Fabrication of
Piping, Section 1.9.2.9, and Exhibit 3, Cold Bending of Pipe, Section 5.
10.2.7.6 Inspection Procedure
SELLER shall provide inspection procedures for the purpose of determining that specified
requirements (e.g. dimensions, properties, performance results, etc.) are met.
In addition, SELLER shall provide measurement and inspection procedures per Exhibit 5,
Shop Fabrication of Piping, Sections 1.9.2.12, 1.9.2.14, and 1.9.2.17.
10.2.7.7 Heat Treatment Procedure
SELLER shall submit a procedure for heat treatment per Exhibit 6, Pressure Vessel Design
and Fabrication, Section 7.1.5.
10.2.7.8 Pressure Test Procedure
SELLER shall submit pressure testing procedures including hydro, air, leak, separation, or
vacuum test procedures for performing hydrostatic or pneumatic structural integrity and
leakage tests per Exhibit 6, Pressure Vessel Design and Fabrication, Section 7.3 and
Section 6.2 of this specification.
10.2.7.9 Hardness Testing Procedure
SELLER shall submit a procedure for hardness testing per Exhibit 6, Pressure Vessel
Design and Fabrication, Section 7.1.3.
10.2.7.10 Wall Thickness Measurement Procedure
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SELLER shall submit a procedure for wall thickness procedure per Exhibit 5, Shop
Fabrication of Piping, Section 1.9.2.12.
10.2.8 Reports
10.2.8.1 Seismic Analysis
SELLER shall provide a seismic analysis as required in Section 3.5.3 of this specification.
Analysis shall demonstrate suitability of materials, components, or systems in relation to the
conditions imposed by the stated seismic criteria.
10.2.8.2 Non-Destructive Examination Records
SELLER shall keep records pertaining to NDE, base materials, filler materials, fabrication,
and inspection in accordance with Exhibit 6, Pressure Vessel Design and Fabrication,
Section 9.4.
10.2.8.3 Test Reports for Vessels and Piping
SELLER shall supply quality records and test results for the following items in accordance
with Exhibit 6, Pressure Vessel Design and Fabrication, Section 9.2. Test reports shall
include, but not limited to:
a) Heat treat reports.
b) Ultrasonic examination and verification reports.
c) Radiographic examination and verification reports.
d) RT film and reader sheets.
e) Magnetic particle examination and verification reports.
f) Liquid penetrant examination and verification reports.
g) Pressure testing and verification reports.
h) Inspection and verification reports.
i) Mechanical test reports.
SELLER shall supply NDE test reports in accordance with the following:
a) Exhibit 4, General Welding and NDE Requirements for Supplier Fabricated
Piping, Section 13.2.1.
b) Exhibit 5, Shop Fabrication of Piping, Sections 1.9.3.4 and 1.9.3.5.
c) Exhibit 3, Cold Bending of Pipe, Section 10.
10.2.8.4 ASME Data Reports
SELLER shall provide ASME Boiler and Pressure Vessel Code Section VIII data reports in
accordance with Exhibit 6, Pressure Vessel Design and Fabrication, Section 9.5.
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10.2.8.5 Positive Material Identification Reports
SELLER shall submit PMI testing reports, including a PMI map per Exhibit 1, Positive
Material Identification (PMI), Section 6.
10.2.8.6 Material Test Reports
SELLER shall submit material test reports (MTR) in accordance with the following:
a) Deleted.
b) Exhibit 4, General Welding and NDE Requirements for Supplier Fabricated Piping,
Section 6.5.
c) Exhibit 5, Shop Fabrication of Piping, Section 1.9.3.2.
d) Exhibit 6, Pressure Vessel Design and Fabrication, Section 4.1.1.
e) 24590-WTP-3PS-MVB2-T0001, Engineering Specification for Welding of Pressure
Vessels, Heat Exchangers and Boilers, Section 6.1.4.
f) Exhibit 10, Technical Supply Conditions for Pipe, Fittings, and Flanges, Section 8.
Material test reports shall be supplied for all alloy and stainless steel construction materials
that make up vessels.
10.2.8.7 Wall Thickness Measurement Reports
SELLER shall submit wall thickness measurement reports per Exhibit 5, Shop Fabrication
of Piping, Section 1.9.3.7.
10.2.8.8 Hardness Test Reports
SELLER shall submit hardness test reports, where required, per Exhibit 6, Pressure Vessel
Design and Fabrication, Sections 7.1.
10.2.8.9 Ferrite Data
SELLER shall submit ferrite data on welding materials in accordance with the following:
a) 24590-WTP-3PS-MVB2-T0001, Engineering Specification for Welding of Pressure
Vessels, Heat Exchangers, and Boilers, Section 6.1.1.
b) Exhibit 4, General Welding and NDE Requirements for Supplier Fabricated
Piping, Section 6.3.
10.2.8.10 Obstruction Reports
SELLER shall certify in writing that all internals are free from obstruction in accordance
with Exhibit 6, Pressure Vessel Design and Fabrication, Section 7.5.
24590-BOF-3PS-MVSC-T0002, Rev 3
DFLAW Effluent Management Facility Atmospheric Process Vessels
Page 22
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
10.2.8.11 Spray Nozzle Performance Reports
SELLER shall provide a test report of each model/type of spray nozzle to list and
demonstrate that the equipment meets the performance criteria listed in the MDS.
10.2.8.12 Inspection Reports
SELLER shall provide inspection reports in accordance with G-321-V, Quality Verification
Document Requirements forms attached to the MR. The reports shall include test data
results, in accordance with the testing requirements in Section 6 of this specification.
10.2.8.13 Eductor and Agitator Performance Reports
SELLER shall provide a test report of each model/type of eductor and agitator to list and
demonstrate that the equipment meets the performance criteria listed in the MDS.
10.2.8.14 Record of any Major Weld Repairs
SELLER shall submit a record for any major weld repairs per Exhibit 5, Shop Fabrication
of Piping, Section 1.9.3.8 and 24590-WTP-3PS-MVB2-T0001, Engineering Specification
for Welding of Pressure Vessels, Heat Exchangers and Boilers, Sections 11.1.13, 11.1.15,
and 12.2.2.
10.2.8.15 Weld Map
SELLER shall submit a weld map for each weld in accordance with 24590-WTP-3PS-
MVB2-T0001, Engineering Specification for Welding of Pressure Vessels, Heat
Exchangers, and Boilers, Section 11. Include NDE/PMI maps on the weld map drawings.
10.2.8.16 Analysis and Design Report
SELLER shall provide analysis and design reports, including analytical data (stress, fluid
dynamics, etc.), which demonstrates that an item satisfies all specified requirements.
10.2.8.17 Deleted
10.2.8.18 Motor Test Report
SELLER shall submit motor test reports in accordance with Exhibit 11, Low Voltage
Induction Motors, Section 5.1.
10.2.8.19 Deleted
10.2.8.20 Deleted
10.2.9 Calculations and Analysis
10.2.9.1 Design Calculations for Vessels
24590-BOF-3PS-MVSC-T0002, Rev 3
DFLAW Effluent Management Facility Atmospheric Process Vessels
Page 23
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
SELLER shall submit design calculations, including code calculations, in accordance with
Exhibit 6, Pressure Vessel Design and Fabrication, Section 9.2.
10.2.9.2 Deleted.
10.2.9.3 Nozzle Loading Calculation
SELLER shall submit nozzle loading calculations in accordance with the Exhibit 6,
Pressure Vessel Design and Fabrication, Section 9.2.
10.2.9.4 Design Life Analysis
This submittal requirement is waived.
10.2.10 Schedules
10.2.10.1 SELLER shall submit sequence of activities required to meet the equipment delivery date.
At a minimum, the schedule shall cover equipment design, procurement, fabrication and
manufacture, tests and inspections, hold and witness points, and production deliverables.
11 Design Changes Incorporated by Reference
24590-WTP-SDDR-MS-17-00103*
24590-WTP-SDDR-MS-17-00105*
* New design changes.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 1, Page 1-1
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
EXHIBIT 1 | POSITIVE MATERIAL IDENTIFICATION (PMI)
Specification 24590-WTP-3PS-G000-T0002, REVISION 9 was used as applicable to create the
following exhibit. Specification change notices (SCNs) have been evaluated and there are no
applicable SCNs.
Note: All References on this exhibit are inclusive to this exhibit only.
Specification Requirement
1 Scope This exhibit covers the minimum requirements for and the extent of application of Positive
Material Identification (PMI) testing of shop fabricated pressure retaining equipment and
piping. This exhibit applies to shop fabrication only.
3 Technical
Requirements
3.1 General The purpose of PMI is to provide evidence that the materials are correctly supplied as
specified by project documents. PMI is required for shop-fabricated items fabricated from
the alloys identified in Table 1.
When required by this exhibit, PMI testing will be done on each component of a pressure
retaining assembly. This shall include each individual segment of pipe, each plate, and all
other pieces of base materials (e.g., forgings, fittings, and tubing) and all required pressure
retaining welds.
For purposes of this exhibit, the following definitions are used:
Alloy: Metallic materials (including welding filler materials) which contain alloying
elements including but not limited to: Chromium (Cr), Nickel (Ni), Molybdenum (Mo),
Copper (Cu) or Tungsten (W).
300 Series Stainless: Austenitic Stainless Steels (304L, 316L, etc.)
6 % Mo: AL6XN, 254 SMO, etc.
Duplex Stainless Steel: CD4MCu, etc.
Nickel Base: Alloy C-22, 625, 690, etc.
3.2 Responsibility The Seller shall submit to the Buyer, for review and comment prior to fabrication,
procedures covering how PMI will be conducted and documented. The Seller's procedures
shall include the instrument manufacturer's procedures and requirements, operator
qualification/re-qualification requirements, instrument calibration method(s), calibration
frequency during testing, criteria for acceptance or rejection, material identification method,
and record keeping.
3.3 Verification
Method
3.3.1 Instruments used for PMI shall be of the type that will provide quantitative, recordable,
elemental composition results for positive identification of the alloy elements present.
a) PMI shall be done per the procedures outlined by the manufacturer of the PMI
instrument being used. Modification of these procedures must be approved by the
Buyer.
b) Each PMI instrument shall be calibrated according to the manufacturer's
requirements.
3.3.2
The methods/instruments listed below are acceptable. In application, they must not be used
in a "go-no-go" mode. The only acceptable objective is the positive identification, listing,
and quantification of the relevant elements listed in Section 7.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 1, Page 1-2
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
a) Portable X-ray fluorescence analyzers. Use is limited to the following instruments or their
equivalent unless prior approval is given by the Buyer:
TN Technologies Alloy Analyzer 9266, 9277 (The Metallurgist XR) or 9288
Outokumpu X-Met 840, or X-Met 880
Niton Alloy Analyzer (800 Series)
Thermo Scientific Niton XL3t Analyzer
Metorex X-Met 920, X-Met 3000TA or X-Met 3000TX Metal Analyzer
Innov-X Systems XT Series Analyzer
Innov-X Systems Alpha 6500 Series Analyzer
Innov-X Systems Delta Model DP-2000, DS-2000, or DC-200 Analyzer
b) Portable optical emission analyzers. Use is limited to the following instruments or their
equivalent unless prior approval is given by the Buyer:
SpectroPort Model TP-07 or TFO-02
Outokumpu ARC-MET 900 or the New Spectrotest
SpectroLab, Spectrotest and Spectrotest Jr.
Any other instrument will require Buyer's approval via the submittal process.
Note: Arc strikes, if any, need not be removed.
3.3.3 In lieu of using portable instruments, chemical analysis can be performed on actual material
samples. Care must be exercised while collecting samples, as contamination can be
contributed by the removal tools. Sample extraction shall not weaken or reduce the
functionality of the component. Laboratory analysis reports shall be traceable to the
individual component from which the sample was taken (See Section 6, below).
3.3.4 Parts that are too small to be tested using an alloy analyzer are exempt from PMI testing. If
such exemption is claimed, the PMI procedure shall specify the minimum part size capable
of being tested.
3.4 Welding
Consumable
Control
In addition to PMI testing required by this exhibit, the Seller shall have in place, and
implement, welding consumable material control systems that can be verified by auditing.
PMI of completed pressure retaining welds is required as indicated in Table 1. Production
"Run Off" weld test coupons may be used for chemical analysis checks.
4 Extent of PMI PMI shall be performed on completed equipment, or assembled parts of equipment, at such
time as to ensure that only verified materials have been used in the fabrication and final
assembly of components. If the assembled equipment configuration prevents PMI of any
individual part, then that part shall be tested prior to assembly and be noted as such on the
PMI documentation.
4.1 Vessels,
Exchangers, Tanks,
Filters and other
Manufactured
Equipment
Vessels, exchangers, and other manufactured equipment shall have PMI testing performed
at the Seller's facilities. This shall include piping and components supplied as part of an
equipment "package" or skid.
4.2 Shop
Fabricated Piping
4.2.1 PMI is required for all piping and piping components, circumferential pressure retaining
welds, and non-autogenous longitudinal welds as indicated in Tables 1 and 2. Note that to
the greatest extent possible (considering minimum size restraints of the PMI analyzer), the
requirements for examining tubing are equivalent to that of piping.
4.2.2 PMI is not required on autogenous welds, fillet welds, or socket welds.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 1, Page 1-3
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
4.4 Valves and
Pumps
PMI of valves and pumps is required for materials as indicated in Table 1 and piping fluid
codes as indicated in Table 2.
4.5 Bulk Materials
(Straight Run
Piping, Fittings,
Stock Valves, Etc.)
PMI is required as indicated in Table 1. Table 2 does not apply.
5 Identification
5.1 General All shop-fabricated items/pieces that have been successfully subjected to the required PMI
shall be marked. The mark shall be durable and last through transportation and receiving
inspection at the Buyer's facility. See Section 7 for items that do not pass PMI.
5.2 Marking
Materials
Marking materials and adhesive tape selected shall not cause corrosion or other harmful
effects. Requirements for marking materials:
The total chloride/flouride content shall not exceed 200 ppm.
The total sulfur content shall not exceed 400 ppm.
The total of low melting point metals such as lead, zinc, copper, tin, antimony, and
mercury shall not exceed 1 percent; of this, mercury shall not exceed 50 ppm.
5.3 Equipment and
Equipment
Components
When it has been verified that the material has a composition consistent with the material
specified, then it must be stamped with letters "PMIV". Use low stress stamps for
identification. Items that cannot be stamped shall have an alternate system of marking. Heat
exchanger tubing shall not be stamped. Any alternate system, and the items for which it will
be used, must have Buyer approval. To the maximum extent possible, the stamping/marking
shall be located for ease of future reference/verification.
5.4 Piping
Materials
When it has been verified that the material has a composition consistent with the material
specified, then a colored adhesive tape, or other approved marking method, shall be applied
at one end to facilitate proper identification.
5.5 Fasteners and
Small Parts
Fasteners and small parts shall be marked in accordance with the Seller's procedure using a
hard marking method, an indelible ink, or paint.
6 Records of PMI Results shall be recorded on PMI report forms, which shall indicate, as a minimum, the
following for each examination:
a) Name of inspector
b) Date of testing
c) Test method, including PMI instrument name and serial number
d) Equipment tag number or pipe spool number (PO number for bulk items) for the
specific piece tested
e) Quantitative analysis results for relevant elements (see Section 7)
A PMI map consisting of assembly and sub-assembly drawings shall be prepared for each
piece of fabricated equipment or pipe spool. The map shall include components and welds
and show the locations of PMI testing.
An extended Shop Spool Sheet shall be provided for each individual spool number where
PMI was done.
In the case of bulk items, PMI results may be submitted in the form of a certificate verifying
that parts were tested according to the requirements of this exhibit. Results shall be reported
by heat/lot and shall include the following:
a) Name of inspector
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 1, Page 1-4
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
b) Date of testing
c) Test method, including PMI instrument name and serial number
d) Type and number of pieces tested
e) Acceptable composition ranges for the relevant elements (see Section 7)
f) Material identified
PMI forms shall become a part of the permanent inspection records. Seller shall submit the
completed forms as part of the Final Document Package when required by the Form G-321 -
V in the Purchase Order.
7 Acceptance,
Rejection and
Retesting
Requirements
All materials tested shall be identified by the PMI instrument as being consistent with the
composition of the specified material. The results shall fall within the chemical composition
requirements of the ASTM, AWS or other applicable material specification allowing for the
accuracy of the instrument. Any questionable PMI result shall be re-analyzed by the same or
another instrument, after verification of proper surface preparation. See Section 7.1, below,
for materials and welds that fail to meet requirements on the second analysis.
The following elements shall be identified and recorded, even if the instrument does provide
immediate identification (e.g. display of "316", "6 Mo", etc.):
Alloy Elements
304, 304L Ni, Cr
316, 316L Ni, Cr, Mo
347 Ni, Cr, Nb
Duplex, 6% Mo, 254 SMO, AL6XN, etc. Ni, Cr, Mo, Cu
Nickel base alloys, C-22, 625, 690, etc. Ni, Cr, Mo, W
Welds joining dissimilar base materials or having filler materials that do not match the base
material composition may include an allowance for dilution. Acceptable composition ranges
for commonly used combinations of base material and weld filler metals are included in
Table 3. Other combinations, when required, shall be identified to the Buyer for approval.
Please note that the only proper use of Table 3 is for assessing dissimilar welds.
7.1 If any material, component, or weld of a type not requiring 100% testing is found to be
unacceptable, all other materials, components, or welds (same heat, lot, etc.) represented by
that failed item shall be considered suspect. The Buyer shall be notified immediately if a
component is confirmed to have failed the PMI. The Seller will then have the following
options, with Buyer concurrence:
a) Scrapping/removing all materials, components, or welds represented by the test
piece (all of that heat, lot, etc.) and replacing with new components or filler metals,
or
b) Performing 100 percent examination of the remainder of the represented materials,
components, or welds, and replacing each item that fails the PMI check, or
c) Verifying correct chemistry by laboratory chemical analysis.
7.2 If questionable values obtained with portable analyzers are verified by laboratory analysis,
the laboratory analysis data shall be used and recorded.
7.3 Any item or component containing materials that have not passed the PMI shall be clearly
marked as "DO NOT USE — PMI FAILED" and segregated from the remainder of the
stock.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 1, Page 1-5
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
Table 1 PMI
Requirements for
Shop Fabricated
Items/Pieces
Table 1 PMI Requirements for Shop Fabricated Items/Pieces
ITEM - (NOTE 1) VERIFICATION REQUIRED
Type 304 & 304L Stainless Steel Components No
Type 316, 316L, & 347 Stainless Steel Components Yes – 100%
6% Mo Components Yes – 100%
Duplex Stainless Steel Components Yes – 100%
Nickel Base Alloy Components Yes – 100%
Alloy Valves Yes – 100% Body and Bonnet Only
Alloy Pumps Yes – 100% Casing Only
Alloy Piping – including non-autogenous longitudinal
welds
(Spools, Fittings, Straight-Run Pipe, and Tubing)
Yes – 100% for 6 % Mo alloys
and Nickel base alloys
Yes – 100% for 316L, used in the
fluid codes listed in Table 2
Alloy Pressure Retaining Welds
Yes – 100% of completed welds
that join material required to have
PMI testing
Bolting — B8M used for Pressure Retaining
Connections
Yes – 5 % of total bolts, minimum
one check per heat
Alloy Heat Exchanger Tubing Yes – 5 % of total tubes, minimum
one check per heat
Venturis Yes – 100% pipes and welds
Note:
1. The following items are exempted unless specifically designated for PMI by the Purchase
Order:
a) All type 304L stainless steel components, piping, and welds
b) Deleted
c) Non pressure-retaining parts, such as baffles, trays, tray clips, supports, pall-rings,
support rings, etc.
d) Non pressure-retaining welds and sections of piping, such as drains, vents,
overflows, etc.
e) Gaskets
f) Instrumentation (except when the instrument is a shop fabricated piping component
placed in-line of a piping system requiring PMI)
g) Internal instruments parts (including pressure retaining parts)
h) Instrument tubing less than 1/2 inch in diameter
i) HVAC ducting
j) Piping components located within piping systems for which PMI is NOT required.
Table 2 Fluid Codes
Requiring PMI
Testing (Shop
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 1, Page 1-6
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
Fabricated Piping
and Piping System
Components)
Table 3 Base
Material and Weld
Filler Metal
Composition
Requirements
(Wt%)
T able 2 Fluid Codes Requiring PMl T e ting ( hop abricated Piping and Piping System
omponents)
FluldCode Fluid Code Fluid Code
DR Suspect GU Nitric Acid Fume GV Vessel Vent Radioactive Steam Radioactive
HN Nitric Acid HR Recovered Nitric PA Radioactive Acid Aqueous
PB LAW Feed PC HLW Feed Slurry PE Entrained Solids Concentrate
PF Csffc Concentrate PH LAW Melter Feed PJ HLW Melter Feed
pp Ultrafi.lter PR Suspect PS Suspect Radioactive Penneate Radioactive Liquid Slurrv
PU Suspect PY Strontium PW Radioactive Radioactive Carbonate Gas/Vapor Gas/Vaoor
PX Radioactive Slurry PZ Waste Feed RK Sodium Permanganate
ZE Plant Wa h Fluid ZF Plant Washing ZH Acidic Effluent
ZJ Al kaline Effiuent ZL Spent lX Resin ZN Neutralized Effiuent
ZR Su pect ZS Process zx Special Radioactive ludioactive Decontaminant Condensate Condensate
ZY Scrubber Effluent
T able 3 Base Material and Weld Filler Metal Composition Requirements (Wt %)
MATERIAL Cr Ni Mo Cu w Notes 304L BM 18.0- 20.0 8.0 - 12.0 --- -- -- -
308L WFM I 9.5 - 22.0 9.0 - 11.0 0.75 max --- --- E/ER308L & LT
304L Welds 18.0- 22.0 8.0 - 12.0 0.7 5 max --- --- Note I
J04LBM 18.0 - 20.0 8.0 - 12.0 --- -- -- -
J 16LBM 16.0- 18.0 10.0 - 14.0 2.0 - J .O -- ---J I6L WFM 17.0 - 20.0 11.0- 14.0 2.0• - 3.0 --- --- E/ERJ16L & LT
J041J316L Welds 16.0 - 20.0 8.0 - 14.0 3.0 max --- --- Nole I
304LBM 18.0 - 20.0 8.0 - 12.0 --- ... ---316L BM 16.0 - 18.0 10.0 . 14.0 2.0 · 3.0 ... ... 308LWFM 19.5 • 22.0 9.0 • 11.0 0.75 DWX ·-- --- E/ERJ08L & LT
304U3 16L Welds 16.0 • 22.0 8.0 • 14.0 3.0 ma.x ... --- Note I
304LBM 18.0 - 20.0 8.0 - 12.0 --- --- ---308L WFM 19.5 - 22.0 9.0 - 11.0 0.75 max --- --- E/ER308L & LT
CD4MCuBM 24.5 - 26.5 4.75 - 6.0 1.75 · 2.25 2.75 - 3.25 ... 304UCD4MCu Welds 18.0 - 26.5 4.75 - 12.0 2.0 max ---
Note 1 ---
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 1, Page 1-7
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
Table 3 Base
Material and Weld
Filler Metal
Composition
Requirements
(Wt%)
Table 3 Base Material and Weld Filler Metal Composition Requirements (Wt %) (cont.)
MATERIAL Cr Ni Mo Cu w Notes 3l6LBM 16.0- 18.0 10.0 - 14.0 2.0-3.0 -- --316L WFM 17.0- 20.0 11.0-14.0 2.0 - 3.0 --- -- E/ER3 16L<
316L Welds 16.0 - 20.0 10.0 - 14.0 2.0 - 3.0 ... -- Note I
316LBM 16.0 - 18.0 10.0 - 14.0 2.0 - 3.0 -- --316L WFM 17.0- 20.0 11.0-14.0 2.0 - 3.0 ... -- E/ER3 16L& LT
CD4MCu BM 24.5 - 26.5 4.75 - 6.0 1.75 - 2.25 2.75 - 3.25 --
316UCD4MCu 16.0 - 26.5 4.75 . 16.0 1.75 - 3.0
Note I Welds
--- --AL6XNBM 20.0 - 22.0 23.5 - 25.5 6.0 - 7.0 0.75 max --
625 WFM 20.0 - 23.0 58.0 min 8.0 - 10.0 0.50 max --- E/ERNiCrMo-3
AL6XNWelds 20.0 • 23.0 25.5 min 7.0 - 10.0 0.75 max --- Note2
C-22BM 20.0 - 22.5 Remainder 12.5 - 14.5 --- 2.5 - 3.5
CD4MCuBM 24.5 - 26.5 4.75 - 6.0 1.75 - 2.25 2.75 - 3.25 --C-22 \VFM 20.0 • 22.5 Remainder 12.5 - 14.5 0.5 max 2.5 - 3.5 E/ERNiCrMo- 10
C-22/CD4MCU 16.0 - 22.5 25.0 min 10.5 • 14.5 2.5 - 4.5
Welds --
C-22BM 20.0 • 22.5 Remainder 12.5 • 14.5 ... 2.5 • 3.5
C-22 WFM 20.0- 22.5 Remainder I 2.5 - 14.5 0.5max 2.5 - 3.5 E/ERNiCrMo-10
C-22 Welds 20.0- 22.5 52.0 min 12.5 - 14.5 -- 2.5 - 3.5 Note I
Alloy 625BM 20.0 - 23.0 58.0 min 8.0 - 10.0 -- --10 304L 18.0 - 20.0 8.0 - 12.0 --- --- --to 316L 16.0 - 18.0 10.0 - 14.0 2.0 - 3.0 ... --62S \VFM 200 - 230 55.0min 8.0- 10.0 0.50 max -- EIERNiCrMo-3
Alloy 625 to 19.0 - 23.0 50.0 min 8.0 min 0.50 max --
304U316L Welds
AL6XN (N08367) 20.0 - 22.0 23.5 - 25.5 6.0 - 7.0 0.75 max --
BM
to 304L 18.0- 20.0 8.0- 12.0 -- --- ---to 316L 16.0- 18.0 l0.0 - 14.0 2.0 - 3.0 --- --625 WFM 20.0- 23.0 55.0 min 8.0- 10.0 0.50 max --- E/ERNiCrMo-3
N08367 to 19.0 - 23.0 25.0 min 4.0-10.0
304U3 l 6L Welds --- ---
BM = Base metal; WFM = Weld filler metal
Notes:
I. Acceptance is based on the combined base metal and WFM spec requirements.
2. Acceptance is based on WFM spec and the expected amount of dilution for molybdenum.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 2, Page 2-1
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
EXHIBIT 2 | STRUCTURAL DESIGN LOADS FOR SEISMIC CATEGORY IV EQUIPMENT
AND TANKS
Specification 24590-WTP-3PS-FB01-T0001, REVISION 6 was used as applicable to create the
following exhibit. Specification change notices (SCNs) have been evaluated and there are no
applicable SCNs.
Note: All References on this exhibit are inclusive to this exhibit only.
Specification Requirement
1.1 General
This exhibit provides structural design loads for Seismic Category IV
(SC-IV) equipment and tanks on the River Protection Project-Waste
Treatment Plant (RPP-WTP) located at the Department of Energy
(DOE) Hanford Site in Richland, Washington.
The seismic categories are derived from the performance categories
defined in DOE-STD-1020-94 (Ref. 2.7). The loads include dead, live,
wind, fluid, earthquake, snow, ashfall, lateral earth pressure, operating
pipe reaction, and thermal loads.
Equipment and Tanks required to perform a nuclear safety function
during and following a seismic event shall be qualified by analysis or
by testing.
This exhibit is to be used in combination with the Main Equipment
Specification, which may include supplemental codes applicable to the
specific Structure, System, or Component (SSC). Appendix B provides
guidance for documenting seismic qualification. In case of conflicts
between this exhibit and other technical requirements in the Main
Equipment Specification, the Seller shall identify such conflicts to the
Buyer in writing and obtain resolutions documented in writing. These
conflicts may also include inconsistency of load definitions, conditions
and combinations as specified by the referenced codes and standards.
1.2 Definitions
EQUIPMENT: Mechanical, electrical, or control system component or
element that is part of a mechanical and/or electrical system.
SC-IV EQUIPMENT/TANK: Equipment/Tank required to be designed
for the SC-IV loads and load combinations provided in this exhibit.
This may include equipment/tank:
A Safety Class (SC) or Safety Significant equipment/tank that has no
natural phenomena hazards (NPH) safety function.
Assigned SC-IV for seismic design per the facility-specific
Preliminary Documented Safety Analysis (PDSA) document or
Documented Safety Analysis document,
Non-safety SSC with no potential for seismic interaction with a safety
SSC
Non-safety SSC with a low interaction potential with a safety SC-III
SSC
IN-STRUCTURE ACCELERATION RESPONSE SPECTRA: The
elastic response spectrum for 5 percent equivalent viscous damping
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 2, Page 2-2
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
used to represent the dynamic effects of the Design Basis Ground
Motion.
REQUIRED RESPONSE SPECTRUM (RRS): The response spectrum
of a motion for which the equipment/tank needs to be qualified by
testing. The RRS is obtained multiplying by the in-structure
acceleration response spectra by a factor of 1.1 .
TEST RESPONSE SPECTRUM (TRS): The response spectrum of the
test input motion. The TRS is developed from the actual time history of
the motion of the test table. The TRS shall envelop the RRS over the
frequency range for which the test is designed.
REQUIRED INPUT MOTION (RIM): The input motion in terms of
acceleration, velocity, and displacement expressed as a function of
frequency; that a device being tested shall withstand and still perform
its intended function.
2 Applicable Documents
2.1 American Concrete
Institute (ACI)
ACI 318-99 Building Code Requirements for Structural Concrete and
Commentary.
2.2 American Concrete
Institute (ACI)
ACI 349-01 Code Requirements for Nuclear Safety related Concrete
Structures and Commentary.
2.3 American Institute of
Steel Construction (AISC)
AISC M016-89 Manual of Steel Construction — Allowable Stress
Design, Ninth Edition.
2.4 American Society of
Civil Engineers (ASCE)
Manuals and reports on Engineering Practice; No. 78, Structural Fire
Protection, ASCE 1992.
2.5 American Society of
Civil Engineers (ASCE)
Minimum Design Loads for Buildings and Other Structures, ASCE 7-
98.
2.6 American Society for
Testing and Materials
(ASTM) International
Material for steel anchor bolts, ASTM F1554 grade 36, unless specified
otherwise on the design drawings.
2.7 Department of Energy
(DOE):
DOE-STD-1020-94 (Including Change Notice #1 dated Jan 1996)
Natural Phenomena Hazards Design and Evaluation Criteria for
Department of Energy Facilities.
2.8 International Conference
of Building Officials (ICBO)
Acceptance Criteria for Seismic Qualification Testing of Nonstructural
Components ICBO AC 156, January 2000.
2.9 International Conference
of Building Officials (ICBO)
Uniform Building code, UBC-97
2.10 Institute of Electrical
and Electronics Engineers
(IEEE)
IEEE Std 344-1987 (R1993) IEEE Recommended Practice for Seismic
Qualification of Class 1E Equipment for Nuclear Power Generating
Stations.
2.12 Institute of Electrical
and Electronics Engineers
(IEEE)
IEEE Std 382-1996, IEEE Standard for Qualification of Actuators for
Power-Operated Valve Assemblies With Safety Related Functions for
Nuclear Power Plants.
2.13 Institute of Electrical
and Electronics Engineers
(IEEE)
IEEE Std 323-1983, IEEE Standard for Qualifying Class 1E Equipment
for Nuclear Power Generating Stations.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 2, Page 2-3
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
2.15 American Society of
Mechanical Engineers
(ASME)
ASME Boiler and Pressure Vessel Code, Section Il, Part D, Subpart 1
(Any edition of the code between 1995 and current edition)
4 Design Loads
4.1 Wind Loads Wind loads shall be calculated per the provisions of ASCE 7-98 (Ref.
2.5), using the following parameters:
Basic wind speed (3-second gust) at a height of 33 feet above ground:
85 mph for SC-IV
Exposure Category: C
Importance Factor: 1.0
4.2 Snow and Ashfall Loads
4.2.1 Snow loads shall be calculated per the provisions of the ASCE 7-98
(Ref. 2.5), using 15 psf ground snow load.
4.2.2 Ashfall loads shall be as follows.
For SC-IV equipment 3 psf
4.3 Earthquake Loads
4.3.1 Earthquake loads on equipment and tanks supported by structures shall
be calculated per the provisions of UBC-97 (Ref 2.9), Section 1632,
using the following parameters:
Ip = 1.0 For SC-IV equipment tanks
Ca = 0.24
ap = 1.0 for rigidly mounted rigid* equipment
= 2.5 for flexible equipment* * and flexibly mounted rigid
equipment
= 1.0 for tanks
* Rigid equipment are defined as those with a fundamental period of
less than or equal to 0.06 seconds (≥17Hz).
** Flexible equipment are defined as those with a fundamental period
of greater than 0.06 seconds (<17Hz).
Rp = 3.0 To be used when equipment is attached directly to structural
steel
= 1.5*** To be used by suppliers unless otherwise specified on the
Main Equipment Specification
*** Based on actual conditions and location, Buyer's Civil, Structural,
Architectural (CSA) personnel may approve an Rp of 3.0 in
calculations.
4.3.2 Earthquake loads for self-supporting tanks (i.e. supported on their own
foundation) shall be calculated per the provisions of UBC-97 (Ref. 2.9),
Section 1634, using the following parameters:
I = 1.0 for SC-IV tanks
Ca = 0.24
Cv = 0.32
4.3.4 For qualification by testing (hard-mounted application), the
requirements presented in either AC 156 (Ref. 2.8), or IEEE Std 344
(Ref. 2.10) shall be followed. The actual mounting of the equipment
shall be either simulated or duplicated. The test duration shall be per
Section 7.6.5 of IEEE Std 344. The seismic load for testing shall be
defined by multiplying the In-Structure Acceleration Spectra as shown
in Section 7 by a factor of 1.1, to obtain the Required Response
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 2, Page 2-4
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
Spectrum (RRS) per Equation 2-6 in DOE-STD-1020-94 (Ref. 2.7) and
enveloping the result to determine the Test Response Spectrum (TRS).
These spectra are for horizontal input motion at 5% damping. For
vertical input motion, use two-thirds of the given horizontal input
motion.
The Seller shall submit the proposed test program to the Buyer for
review prior to testing.
See Appendix D for Additional Seismic Qualification
Requirements/Guidelines.
To qualify by previous testing, the methodology shall be approved in
advance by the Buyer, see Appendix B, section 2(k) of this exhibit for
further guidance.
4.3.5 The Seller shall submit the proposed test program (test plan) to the
Buyer for review prior to testing.
Test plan and sequence, as referenced by IEEE Std 344 (Ref. 2.10) and
IEEE Std 382 (Ref.
2.12), shall be per Sections 6.3.1.1 and 6.3.2 of IEEE Std 323 (Ref.
2.13), respectively.
For qualification (line or duct-mounted application), see Appendix D.
4.5 Live Loads on
Equipment-Supported and
Tank-Supported Platforms
and Walkways
Platforms and Walkways 100 psf
Stairs treads 100 psf or 300 lbs. concentrated loads applied over an
area of four (4) square inches, whichever load produces greater effect
on equipment.
Handrails for stairs and platforms Per Table 16B of UBC-97 (Ref. 2.9)
4.6 Thermal Loads
4.6.1 Base Temperature The base temperature for thermal analyses shall be 70oF. This
temperature is based on recommendations from ACI 349 (Ref. 2.2).
4.6.2 Outdoor Ambient
Temperatures
Unless specified otherwise in the Main Equipment Specification or
datasheets, ambient air temperatures shall be as follows:
For SC-IV equipment:115 oF maximum, -25 oF minimum
4.6.3 Operating
Temperatures (Normal and
Abnormal), To
Operating (normal and abnormal) temperatures are provided in Main
Equipment Specification or the Equipment Qualification Datasheets
(EQDs). Abnormal Temperatures are due to an anticipated eight-hour
loss of cooling event, which is postulated to occur once per year, and is
not the result of an accident or NPH. Abnormal temperature thermal
loads shall not be considered concurrent with earthquake (E) loads. For
load combinations which include earthquake (E), To shall be normal
operating temperature thermal loads only. For load combinations
without seismic (E), To shall be greater of normal or abnormal
operating temperature thermal loads.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 2, Page 2-5
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
4.6.4 Accident Temperatures
(Design Basis Event), Ta
Accident temperatures are associated with the Design Basis Event
(DBE) and provided in the Main Equipment Specification or EQDs ,
unless noted otherwise in Section 5 of this exhibit and are described as:
a) High energy line break (HELB). Which are to be considered
concurrent with NPH loads in accordance with the appropriate codes.
b) Loss of facility cooling combined with extreme outdoor
temperatures. This load and NPH Temperature load shall not be
considered concurrent with earthquakes ( E ) loads.
4.6.5 Temperature
Limitations on Structural
Elements
SC-IV designed steel and stainless steel structures shall use reduced
yield stress (Fy) and elastic modulus (E) in accordance with the ASCE
Engineering Practice 78 (Ref. 2.4), see example provided in Appendix
A.
5 Loads and Load
Combinations
The following loads and load combinations are applicable to SC-IV
equipment and tanks.
5.1 Structural Steel Design
Load Combinations
For the design of equipment and tanks, the following loads shall be
combined with other applicable loads, per the provisions of the
Equipment/Tank Technical documents included with the Purchase
Order (P.O.).
A Ashfall Loads
D Dead Loads
E Earthquake (Seismic) Loads (Due to DBE)
L Live Loads
SN Snow Loads
W Wind Loads
To Thermal Loads during Normal & Abnormal Operating Conditions
Ta Thermal Loads due to Accident (DBE) Temperature
Po Maximum or minimum differential pressure load generated by
Normal or Abnormal HVAC operations
Pa Maximum or minimum differential pressure load generated by DBE
HPAVdef Pipe reactions due to HPAV high-speed deflagration loading
HPAVdet Pipe reactions due to HPAV detonation
S Allowable Stress per Allowable Stress Design Method
For the design of equipment/tank supports, the following service-level
load combinations shall apply. Note: the 1/3 allowable stress increase
discussed in UBC-97 (Ref. 2.9), Section 1612.3.2, has been
incorporated into the following combinations through the use of the
0.75 factor. No further stress increase is allowed.
The following load combinations are based on Section 1612.3.2 of
UBC-97 and using the Allowable Stress Design Values of AISC M016,
ASD Ninth Edition (Ref. 2.3).
S = D+L+A+Po+To
S = D+L+SN+Po+To
S = 0.75(D+L+W+Po+To)
S = 0.75(D+L+SN/2+W+Po+To)
S = 0.75(D+L+SN+W/2+Po+To)
S = 0.75(D+L+Po+To+E/1.4)
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 2, Page 2-6
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
S = 0.75(0.9D+Po+To±E/1.4)
S = 0.75(D+L+Pa+Ta)
S = 0.75(D+L+Ta+E/1.4) Where Ta is Due to HELB
5.1.1 Structural Steel Design Load Combinations for HPAV shall be
consistent with Section 5.1 with the following exceptions:
• HPAVdef load combinations are as follows:
S = D+L+Lr+A+HPAVdef)
S = D+L+SN+HPAVdef)
S = 0.75(D+L+W+HPAVdef)
S = 0.75(D+L+SN/2+W+HPAVdef)
S = 0.75(D+L+SN+W/2+HPAVdef)
• HPAVdet load combination is as follows: S = 0.75 (D+L+HPAVdet)
S = 0.75(D+L+W+HPAVdet)
5.1.2 Other Loads Where other loads are to be considered in design, each applicable load
shall be added to the combinations specified above per requirements of
Section 1612.3.3 of UBC-97 (ref. 2.9).
5.2 Reinforced Concrete
Design Load Combinations
(Anchorage design)
For equipment and tanks anchorage design, the following loads shall be
combined with other applicable loads, per the provisions of the Main
Equipment Specification.
A Ashfall Loads
D Dead Loads
E Earthquake Loads
F Fluid Loads
H Lateral Earth Pressure Load
L Live Loads
Ro Operating Pipe Reaction Load
SN Snow Loads
To Thermal Loads during Normal & Abnormal Operating Conditions
W Wind Loads
Ta Thermal Loads due to Accident (DBE) Temperature
Po Maximum or minimum differential pressure load generated by
Normal or Abnormal HVAC operations
Pa Maximum or minimum differential pressure load generated by DBE
U Required Strength per Strength Design Method
The following load combinations are based on section 9.2 of ACI 318
(Ref. 2. l ).
U = 1.4D + 1.7L + 1.7A
U = 1.4D + 1.7L + 1.7SN
U = 0.75(1.4D + 1.7L + 1.7W)
U = 0.75 (1.4D + 1.7L + 1.7SN + 1.7W)
U = 0.9D ± 1.3W
U - 1.4D + 1.7L+ 1.7A + 1.7H
U = 1.4D + 1.7L + 1.7SN+ 1.7H
U = 0.9D + 1.7H
U = 1.4D + 1.7L+ 1.7A + 1.4F
U = 1.4D + 1.7L + 1.7SN + 1.4F
U = 0.9D + 1.4F
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 2, Page 2-7
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
U = 1.4 (D + To)
In addition, the following load combinations based on UBC Section
1612.22 shall apply.
U= 1.1(0.9D±E)
U = 0.75(1.4D+1.7L+1.7SN+1.4Ta+1.4Ro) Where Ta is Accident
(DBE) Temperature [see 4.6.4(b)]
U = D+L+SN+F+H+Ta+Ro+E where Ta is due to (HELB) [see 4.6.4(a)]
U = 0.75(1.4D+1.7L+1.4To+1.4Po+1.4Ro)
U = 0.75(1.4D+1.7L+1.7SN+1.4To+1.4Po+1.4Ro)
U = 1.4(D+To+Po)
U = 1. 1 (1.2D+L+0.2SN+1.3F+1.6H+ 1.2To+1.2Po+1.2Ro+E) where
To and Po are the normal operating values only
U = 0.75(1.4D + 1.7L + 1.7SN+ 1.4Ta+ 1.4Pa + 1.4Ro)
U = D + L + SN + F + H + Ta + Pa + Ro
6 Equipment and Tank
Anchorage
The Supplier shall furnish the Buyer with the following information:
• Location of anchorage in relation to equipment.
• Design loads on the anchorage shall be reported by individual load
and load combination.
• Coordinate system and sign conventions.
The selected anchor bolt material for the WTP project is ASTM F1554
(Ref. 2.6). Use of other anchor bolt materials, require the approval of
the Buyer.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 3, Page 3-1 24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
EXHIBIT 3 | COLD BENDING OF PIPE
Specification 24590-WTP-3PS-PS02-T0002, REVISION 2 and its associated Specification
Change Notice (SCN) 24590-WTP-3PN-PS02-00111 were used as applicable to create the
following exhibit.
Note: All References on this exhibit are inclusive to this exhibit only.
Specification Requirement
1 Scope This exhibit establishes the requirements for Shop and Field cold bending of stainless
steel pipes.
2 Applicable Documents
Work shall be done in accordance with the referenced codes, standards, and documents
listed below, which are an integral part of this exhibit. The following codes and
standards shall apply:
ASME B31.3 - 1996 Process Piping
PFI ES-3 Fabricating Tolerances
PFI ES-24 Pipe Bending Methods, Tolerances, Process and Material Requirements
3 Materials Cold bending is permitted for seamless ASTM A312 Type 304L and Type 316L
stainless steel pipe. Pipe may be cold bent by rotary draw bending or ram and roll
bending. Material allowances will vary with the cold bending method, material, pipe
size and bend radius and are dependent upon the equipment used. The maximum size
pipe to be bent shall be 4 NPS Schedule 80S for stainless steel. Bending is restricted to
3-D or larger radius bends. The wall thickness after bending shall not be less than 70%
of the specified pipe class schedule nominal wall thickness for Buyer designed piping.
Thinning that exceeds that allowed in the pipe class shall be brought to Buyer's
attention via a Supplier Deviation Disposition Request. For Supplier designed piping,
the wall thickness after bending shall not be less than the minimum required thickness
calculated in accordance ASME B31.3-1996, Paragraph 304.2.1.
4 Qualification Testing
4.1 Qualification testing shall be performed in accordance with ASME B31.3 and this
exhibit. Sample bends shall be made using Schedule 40 pipe with the minimum bend
radius used in production, or smaller.
5 Bending Procedure The Shop and Field Fabricator shall submit a detailed procedure for review and
acceptance prior to use. Procedure shall include the bending method to be used,
equipment descriptions, lubricants, inspections, and documentation.
6 Acceptance Criteria
6.1 Pipe bends shall be free of cracks, seams, gouges, and notches and be free of any
indication of buckling. Minor defects shall be removed by grinding or buffing provided
the thinning allowance permitted by the Pipe Class Sheet is maintained. Bends with
cracks or other major defects shall be rejected.
6.2 Pipe bend dimensional tolerances shall be in accordance with ASME B31.3, the Pipe
Class Sheets, and as follows:
6.2.1 Degree of bend ±1.0 degree
6.2.2 Plane of bend ±1.0 degree
6.2.3 Linear PFI ES-3
6.2.4 Minimum Radius and tangent PFI ES-24
6.2.5 Ovality
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 3, Page 3-2 24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
6.2.5.1 Ovality shall not exceed 8 % of the nominal outside diameter [Ovality % = (Dmax - Dmin)
x 100 / Dnom]
6.2.5.2 Ovality shall be checked at the bend start, finish, 1/4, mid, and 3/4 points on the first
five bends with each procedure for each diameter and schedule or wall thickness on
each shift.
6.2.5.3
If Ovality test results are acceptable, the ovality test may be reduced to a single test at
the mid point of 10 % of the bends for the remainder of the shift, as long as the ovality
remains acceptable.
6.2.5.4 If any bend is found with Out of Tolerance Ovality, all previous bends from that
procedure shall be verified by the full ovality check (start, finish, 1/4, mid, and 3/4).
6.2.5.5 Full ovality testing may again be reduced after five consecutive acceptable full
examinations.
6.2.6 Wall Thickness
6.2.6.1 Wall thickness measurements shall be made along the extrados at the start, finish, 1/4,
mid, and 3/4 points on the first five bends with each procedure on each shift. The
measured wall thickness shall not be less than 70% of the specified pipe class schedule
nominal wall thickness for Buyer designed piping. For Supplier designed piping, the
wall thickness after bending shall not be less than the minimum required thickness
calculated in accordance ASME B31.3-1996, Paragraph 304.2.1.
6.2.6.2 If wall thickness measurements are acceptable, all subsequent bends made with the
same procedure on the same shift of the same diameter and schedule or wall thickness
of pipe shall have wall thickness measurements taken at the location of greatest
thinning only.
6.2.6.3 If any bend is found with Out of Tolerance Thickness, all previous bends from that
procedure shall be verified by the full thickness check (start, finish, 1/4, mid, and 3/4).
6.2.6.4 Full wall thickness testing may again be reduced after five consecutive acceptable full
examinations.
9 Materials for Use In
Contact with Stainless
Steel
9.1 The thinners, solvents, and cleaning materials that are to be used in direct contact with
austenitic stainless steels shall meet the following requirements:
The leachable halogen content shall be less than 200 ppm.
The leachable sulfur content shall not exceed 400 ppm.
Low melting points metals (lead, bismuth, zinc, mercury, antimony, cadmium,
and tin) shall not exceed 1 percent. Of this, mercury should not exceed 50 ppm.
These low melting point metals shall not be intentionally added to materials in
direct contact with austenitic stainless steels.
9.2 Bending lubricants shall be thoroughly removed using an approved cleaning procedure
after bending is complete.
9.3 A certificate of analysis for bending lubricants to be used shall be included with the
bending procedure.
10 Documentation and
Submittals (Applicable to
Shop Fabrication Only)
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 3, Page 3-3 24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
10.2 The Supplier shall submit dimensional tolerance acceptance verification in accordance
with this exhibit and the Purchasing documents. Verification reporting format may be
either by tabular listing of reports or by tabular listing and sketch, and specified by
Supplier's accepted procedure.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility
Atmospheric Process Vessels
Exhibit 4, Page 4-1
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
EXHIBIT 4 | GENERAL WELDING AND NDE REQUIREMENTS FOR SUPPLIER
FABRICATED PIPING
Specification 24590-WTP-3PS-NWP0-T0001, REVISION 2 and its associated
Specification Change Notices (SCNs) 24590-WTP-3PN-NWP0-00003, 24590-WTP-3PN-
NWP0-00006, and 24590-WTP-3PN-NWP0-00004 were used as applicable to create the
following exhibit.
Note: All References on this exhibit are inclusive to this exhibit only.
Specification Requirement
1 Scope This exhibit establishes the welding, nondestructive
examination (NDE), and heat treating requirements for
Supplier-fabricated piping and is applicable to purchase orders
for equipment as well as to piping fabrication purchase orders
(i.e., the fabrication of pipe spools).
2 Applicable Documents
2.2 Codes and Standards For codes and standards listed below, the specific revision or
effective date identified, as well as the specific revision or
effective date of codes and standards that they incorporate by
reference (daughter codes and standards), shall be followed. If a
date or revision is not listed, the latest issue, including the
addenda, at the time of award shall apply unless otherwise
specified in the purchase order. The use of any other edition,
revision, or issue requires Buyer's approval. Conflicts shall be
referred to the Buyer for resolution.
2.2.1 American Society of Mechanical Engineers (ASME)
B31.3 1996 Process Piping
Section II 1995 Boiler & Pressure Vessel Code,
Section Il, Materials
Section V 1995 Boiler and Pressure Vessel Code,
Section V, Nondestructive
Examination
Section
IX
1995 Boiler and Pressure Vessel Code,
Section IX, Welding and Brazing
Qualifications
2.3 American Society for Nondestructive Testing (ASNT)
SNT-TC-
1A
* Recommended Practice No. SNT-TC-
1A Personnel Qualification and
Certification in Nondestructive Testing
*Personnel who perform NDE (including radiographic testing,
magnetic particle testing, ultrasonic testing, liquid penetrant
testing, electromagnetic testing, neutron radiographic testing,
leak testing, acoustic emission testing, and visual testing) to
specified acceptance criteria shall be qualified to a "Written
Practice" (or procedure) meeting the requirements of the
American Society for Nondestructive Testing Recommended
Practice No. SNT-TC-1A. This "Written Practice" must meet all
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility
Atmospheric Process Vessels
Exhibit 4, Page 4-2
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
the requirements from any one given edition of SNT-TC-1A
(and its applicable supplements) as follows: 1988, 1992, 1996,
2001, and 2006. Only the SNT-TC-1A edition selected and its
applicable supplements shall be used in the "Written Practice"
and that edition shall be met in its entirety
(except as shown below). Combining SNT-TC-1A contents
from one edition year with another edition year is prohibited,
except as follows:
If the 1988, 1992, or 1996 editions are utilized, the additional
requirements for periodic technical performance evaluation and
documentation found in paragraphs 10.2 and 12.1 of the 2006
Edition shall also be met.
The re-certification interval for Level Ill nondestructive
examination personnel shall not exceed five years.
2.4 Reference Documents
2.4.3 Exhibit 5 of 24590-BOF-3PS-MVSC-T0002 , Shop Fabrication
of Piping
3 Definitions
3.4 Supplier-Fabricated: performed at the Supplier's facility.
4 Submittal of Procedures
4.1 Before any fabrication is to commence, procedures for welding,
control and storage of filler material, hardness testing, and
postweld heat treatment (PWHT) shall be submitted to the
Buyer for review against Code requirements and for suitability
for each intended application. Additionally, the Seller shall
submit a detailed Welding Procedure Application List
identifying Welding Procedures being used for each individual
pipe material. This document will also identify the extent of
NDE per individual pipe material and the extent of Positive
Material Identification (PMI). Exhibit 5 of 24590-BOF-3PS-
MVSC-T0002 covers the extent of NDE and PMI. The attached
form (Figure 1) is a typical example of a Welding Procedure
Application List. The submittal of procedures for review
applies to any sub-vendor used by the Supplier. A review status
of "Work May Proceed" shall be obtained prior to use. Early
submittal is necessary to allow time for possible revision.
4.3 Welding procedures shall be qualified in accordance with the
requirements of the applicable Code and any additional
requirements defined on the Welding Procedure Application
List. The procedure qualification record (PQR) shall be
submitted with the welding procedure specification (WPS).
Personnel qualifications will be verified at the Supplier's shop.
4.4 It is not the Buyer's intent to require revisions to the Supplier's
standard WPSs to meet these requirements, yet the limitations
shall be clearly acknowledged and the instructions employed by
the welders on the shop floor. To accommodate this, Supplier's
may revise WPSs or issue job-only amendments or addenda to
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility
Atmospheric Process Vessels
Exhibit 4, Page 4-3
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
standard WPSs. Any amendment or addenda shall become part
of the WPS for the purchase order and shall be issued to the
welders employed in the work.
4.5 For repair of a weld, either the original WPS or one originally
submitted as a designated repair WPS shall be used.
4.6 Repair plans that use welding for repair of welds or base metals
shall be submitted to the Buyer for review and permission to
proceed prior to the start of the repairs. A repair plan shall
include the following:
a) The method of evaluating the type and the extent of the
defect.
b) Methods used for removing the defect, and testing conducted
to ensure that the defect has been removed.
c) Welding procedure employed and NDE methods used to
inspect the completed repair.
Any incident of breaching the pressure boundary will require
the submittal of a repair plan, specific to the incident, to the
Buyer for review and permission to proceed prior to the start of
the repairs.
4.7 Postweld heat treatment procedures describing cleaning
requirements, heating and cooling rates, thermocouple
locations, type of heating equipment, etc. shall be submitted to
the Buyer for review and permission to proceed if required per
ASME/ANSI B31.3 Code.
5 Welding Process
Limitations
5.1 Root Pass of Single
Side Butt Welds Without
Backing
Subject to the limitations listed, only the following welding
processes shall be used:
5.1.1 Shielded Metal Arc Welding (SMAW)
a) EXX10 or EXX11 electrodes on P-No. 1, S-No. 1, S-No. 3,
P-No. 3, SP-1, SP-2, and SP-3 (see B31.3) steels.
b) Maximum electrode diameter of 3/32 inch for nominal pipe
size (NPS) less than 2-1/2 inch.
c) EXX10, EXX11, EXX12, and EXX13 limited to impact test
temperature not lower than -20°F.
5.1.2 Gas Tungsten Arc Welding (GTAW)
a) Backpurge two layers minimum for alloy content higher than
2-1/4 wt % Cr and 1 wt % Mo.
b) GTAW is required for all lubrication, hydraulic and
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility
Atmospheric Process Vessels
Exhibit 4, Page 4-4
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
instrument piping (lines).
c) Filler material addition is required, except for thin wall
expansion bellows and titanium.
5.1.3 Gas Metal Arc Welding (GMAW)
a) Globular transfer with mixed gas or CO2.
b) Pulsed spray transfer.
c) Short circuiting transfer using solid wire and shielding gas
neutral to the base metal.
d) For nominal pipe sizes (NPS) less than 6 inch, all shop
welding should be performed in the 1G rotated position
whenever possible.
5.2 Other Than Open Butt
Root Passes (Fill and cap
passes, sockets, fillets)
Subject to the limitations listed, only the following welding
processes shall be used:
5.2.1 Shielded Metal Arc Welding (SMAW)
a) Maximum electrode diameter 3/32 inch on socket welds.
b) Filler metal "F" numbers (see ASME IX-QW-432).
F1 & F2 - not permitted on pressure retaining welds.
F3 - not permitted for welding on castings.
- acceptable for P-No. 1 with 0.30% maximum carbon or 70
ksi maximum ultimate tensile strength.
- not permitted for use when base material requires impact
testing below -20°F (minus 20°F).
F4 - Maximum electrode diameter 3/32 inch for NPS less than
2-1/2 inch.
5.2.2 Gas Tungsten Arc Welding (GTAW)
a) All groove welds in 1-1/2 inch NPS and smaller shall be
welded with GTAW.
5.2.3 Gas Metal Arc Welding (GMAW)
a) GMAW-P - Pulsed spray transfer — No limitations.
b) GMAW-S - Short circuiting or globular transfer - maximum
base metal thickness 3/8 inch.
c) Continuous spray transfer - No limitations.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility
Atmospheric Process Vessels
Exhibit 4, Page 4-5
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
d) For nominal pipe sizes (NPS) less than 6 inch, all welding
shall be performed in the 1G rotated position.
5.2.4 Flux Cored Wire Arc Welding (FCAW)
a) Arc shielding gas required for pressure retaining welds.
5.2.5 Submerged Arc Welding (SAW)
a) Six inch NPS minimum.
b) Neutral flux (no active or alloy).
c) Run on/run off tabs where possible.
6 Welding Filler
Materials
6.1 Except where specifically accepted otherwise, welding
materials shall be selected so that the deposited weld metal is
similar in chemical composition and not significantly harder or
stronger than the base material (e.g., Stainless steel L-grade
base metal shall be welded with L-grade filler metal). Test
temperature shall be at or below the design metal temperature.
6.2 E6013 electrodes may be used for joints in cement lined pipe
with prior permission from Buyer.
6.3 Austenitic stainless steel (A-No. 8) welding materials for
pressure boundary and load bearing welds shall contain a
minimum delta ferrite content of five percent. Compliance with
the ferrite requirements may be based upon the certified
chemical analysis and the WRC Delta Ferrite Diagram (Figure
1) or a ferrite gage complying with AWS A4.2. Alternately, for
SMAW and solid wire filler material manufactured in the USA,
a Certified Material Test Report (CMTR) of minimum ferrite
content is acceptable.
6.4 For dissimilar welds, such as carbon or low alloy steels to
austenitic stainless steels, the Welding Procedure Application
List shall specify the correct filler material type. When postweld
heat treatment of these joints is required, the carbon or low alloy
steel member shall be "buttered" with the selected stainless steel
or nickel alloy (when the design temperature exceeds 800 °F)
filler material, and postweld heat treated. Then the joint shall be
welded to the austenitic stainless steel member without further
PWHT.
6.5 For all filler metal, a Material Test Report (MTR) with actual
test results is required for each heat. Alternatively, a Certified
Material Test Report (CMTR) in accordance with ASME Boiler
and Pressure Vessel Section II, Part C, is acceptable.
6.6 The storage, baking and drying of all welding consumables (i.e.,
covered electrodes, flux cored electrodes and fluxes) shall be as
recommended by the manufacturer. Segregation of carbon steel,
low alloys, and alloy consumables is required during storage,
baking, holding, and handling (including portable ovens).
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility
Atmospheric Process Vessels
Exhibit 4, Page 4-6
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
7 General Welding
Requirements
7.1 All welding shall be protected from wind, rain and other
harmful weather conditions which may affect weld quality.
7.2 All surfaces to be welded shall be dry and substantially free of
mill scale, oil, grease, dirt, paint, galvanizing, and other
contaminants. The welding to austenitic stainless steels or
nickel alloys to attachments which have been coated with
galvanizing or zinc type paint, even if the coating has been
removed, is prohibited.
7.3 Weld bevel preparations for P-No. 4 and higher alloys shall be
machined or ground back to bright metal if they have been
flame, arc, plasma, or laser cut.
7.4 Permanently installed backing rings or straps shall not be used.
Temporary backing requires Buyer approval prior to use.
7.5 The individual weld layer thickness for all processes shall not
exceed 3/8 inch for materials less than 1-1/4 inch thick, or 1/2
inch for greater material thicknesses.
7.6 All weld joints for pressure retaining applications shall have a
minimum of two passes. This includes socket welds.
7.7 Where joints are welded from both sides, the first pass shall be
backchipped, ground or arc-gouged to sound metal before
welding the second side. This requirement shall be stated on the
WPS. (Except on welds that are not full-thickness.)
7.8 Peening shall not be used. The use of pneumatic tools or steel
shot for slag removal is not considered peening.
7.9 Welding sequences in which a layer is not completed before the
next layer is started (block welding) shall require approval by
the Buyer.
7.10 Except for root passes, vertical welding shall be vertical up
unless approved otherwise by Buyer for each specific
application.
7.11 Gas mixture combinations for weld shielding and purging shall
be documented and approved as part of the welding procedure
specification (WPS). Any change in gas mixture requires
revision of the WPS and may require requalification. Welding
consumables shall be qualified using the gas mixture of the
WPS.
7.12 Welding of stainless steel and nickel based materials shall be
physically separated from carbon steel to ensure contamination
by tools, grinding dust, etc., does not occur.
8 Preheat And Interpass
Temperatures
8.1 Preheat temperature shall be in accordance with the applicable
codes and Welding Procedure Application List, except that code
recommended minimum preheat temperatures shall be
mandatory. Preheat requirements shall apply to all welding,
including tack welding and welding of temporary attachments.
Preheat requirements also apply to all thermal gouging and
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility
Atmospheric Process Vessels
Exhibit 4, Page 4-7
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
cutting operations except for P-No. 1 steels. For GTAW root
pass welding only, reduced preheat levels as permitted by the
applicable code may be used. Preheat shall be maintained a
minimum of 3 inches on either side of the joint.
8.2 For welds requiring preheating, the weld joint shall be
completed with no intermediate cooling except that cooling
under an insulating blanket is permitted provided at least
applicable code required minimum joint depth has been filled,
and provided that applicable documents do not specify more
stringent requirements.
8.3 The interpass temperature shall not exceed:
350 °F for austenitic stainless steels and nickel base
alloys
800 °F for hard facing of low carbon austenitic stainless
steels
300 °F for superaustenitic stainless steels, with heat
input not exceeding 50KJ/in
8.4 Preheat shall be determined by temperature indicating crayons,
contact pyrometers or other equally suitable means.
Temperature indicating crayons used on austenitic stainless
steels and nickel base alloys shall not cause corrosive or other
harmful effects. It is the Seller's responsibility to determine
suitable brands that may be used. This information shall be
made available to the Buyer's representative on request.
8.5 If oxy-fuel torches are used for preheating, the torch tip shall be
appropriate for the work (i.e., a "rosebud," not a cutting or
welding tip).
9 Postweld Heat
Treatment (PWHT)
9.1 Postweld heat treatment requirements for piping shall be in
accordance with the applicable code and project specifications.
The heat treatment temperature range and time at temperature
shall be as specified in the Welding Procedure Application List.
9.2 Direct impingement by furnace burner flames is not permitted.
9.3 Only resistance, induction, furnace or quartz lamp heating
methods are permitted. Exothermic heat treatment is prohibited.
9.4 All PWHT cycles shall be recorded on print out charts.
Thermocouples shall be independently recorded. When PWHT
is performed outside of a controlled furnace environment, each
weld shall have at least one thermocouple attached for
temperature monitoring. The heat treat chart shall be submitted
to the Buyer for review.
10 Non-destructive
Examination
10.1 Welding Procedure Application List shall identify the extent of
NDE per individual pipe class and the extent of PMI to address
the NDE and PMI requirements of Exhibit 5 of 24590-BOF-
3PS-MVSC-T0002.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility
Atmospheric Process Vessels
Exhibit 4, Page 4-8
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
11 Workmanship And
Inspection
11.1 Each layer of welding shall be smooth and free of slag
inclusions, porosity, excessive undercut, cracks and lack of
fusion prior to beginning the next layer. In addition, the final
weld layer shall be sufficiently free of coarse ripples, non-
uniform bead patterns, high crown and deep ridges to permit the
performance of any required inspection. All arc strikes, starts,
and stops shall be confined to the welding groove or shall be
removed by grinding. Welds containing cracks shall be locally
repaired.
11.2 Marking materials and liquid penetrant materials used on
austenitic stainless steels and nickel-base alloys shall not cause
corrosive or other harmful effects. See 8.4 of this exhibit.
11.3 Socket welds shall have a gap of 1/16 inch minimum to 1/8 inch
maximum between the bottom of the socket and the end of the
pipe prior to welding.
11.4 Misalignment (high-low) in butt joints shall not exceed
applicable code requirements.
11.5 Deposited weld metal shall meet the hardness requirements
identified on the Welding Procedure Application List. Testing
shall be done after any postweld heat treatment. Hardness
readings shall be taken with a portable tester in accordance with
ASTM or approved equivalent Standards. Hardness
measurements taken as part of a weld procedure qualification
shall be taken on weld transverse cross sections. Hardness
measurements shall be taken as near as practicable to both the
inside and outside diameter surfaces. If a hardness test fails to
meet the acceptance criteria and either of two subsequent
adjacent tests exceeds the specified hardness, the weld shall
either be replaced or reheat treated and retested.
11.7 Each weld shall be marked with the welder's unique symbol or
number identification using low stress stamps or "vibro-etch".
Alternate method(s) shall be submitted for Buyer review and
approval.
11.8 All examination and inspection reports, including radiographic
film, shall be made available to Buyer's representative.
11.9 All nondestructive examinations, including visual examination,
shall be performed by personnel certified in accordance with
ASNT Recommended Practice SNT-TC-1A. Alternatively,
personnel performing visual examinations may be qualified in
accordance with AWS QC-1 as either a CWI (Certified Welding
Inspector) or a SCWI (Senior Certified Welding Inspector). The
Supplier NDE certifications and procedures shall be submitted
to the Buyer for review and permission to proceed.
13 Documentation and
Submittals
13.2 Inspection and Test
Reports
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility
Atmospheric Process Vessels
Exhibit 4, Page 4-9
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
13.2.1 Nondestructive examination test reports shall be provided at the
time of shipment.
13.3 Procedures and
Qualifications
13.3.1 Welding/weld repair procedures and procedure qualification
records shall be submitted prior to the start of work.
13.3.2 Welder, heat treat, and NDE personnel certifications or
qualifications shall be made available to the Buyer prior to the
start of work.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric Process Vessels
Exhibit 4, Page 4-10
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Piping Classes
Design Code: I Category:
Pip: Class(es): Line Services: Limi~: _:_!emperature ' F. •c I Pressur~p~. pars - ---- -- -- ·---
··--
--- .__ ----- ---·-
Piping Material Type: P Number: I Hardness Reauirements:
CVN Requirements: I PMI Requirements:
I Ferrite Requirements:
MaxW.T. Heat Treatment ' ~
Pipe Class or Weld Pipe Size 0 S<:hcd. Joint ~F °C Welding Procedure Specification(s) NDE (%)
Description (nps) 0 inches Type PRE POST RT MT PT VT Other
0mm
Notes:
Figure 1-- Welding & NDE MATRIX (Welding Application List)
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric Process Vessels
Exhibit 4, Page 4-11
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Figure 2 - WRC Delta Ferrite Diagram
21
z ~ ~
20
m .0 C 19 :c· ., (D
a II 18
* ~ + 17 w 0 X
* 16 9 + w 0 15 X
* .3 14 + 0
"' X 13
* ;: 2-
12
11
10
16 17
Austenite
18 19 20 21 22 23 24
Chromium Equivalent ~ % Cr+ % Mo + (1.5 x % Si) + (0.5 x % Cb)
GENERAL NOTE:
The actual nitrogen content is preferred. If this is not available, the following applicable
nitrogen value shall be used:
Austenite + Ferrite
25 26
a) GMAWwelds--0.08% (except self-shielding flux colored electrode GMAW welds--0.12%)
b) welds of other processes--0.06%
27
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility
Atmospheric Process Vessels
Exhibit 5, Page 5-1
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
EXHIBIT 5 | SHOP FABRICATION OF PIPING
Specification 24590-WTP-3PS-PS02-T0001, REVISION 10 and its associated
Specification Change Notices (SCNs) 24590-WTP-3PN-PS02-00088, 24590-WTP-3PN-
PS02-00090, 24590-WTP-3PN-PS02-00103, 24590-WTP-3PN-PS02-00106, and 24590-WTP-
3PN-PS02-00108 were used as applicable to create the following exhibit.
Note: All References on this exhibit are inclusive to this exhibit only.
Specification Requirement
1 General
1.1 Scope This exhibit defines the requirements and the work necessary for
fabrication of piping subassemblies (pipe spools) in accordance
with the requirements of ASME B31.3, Process Piping, other
codes and standards, and documents as referenced in this exhibit.
This exhibit applies to all quality levels as specified by the
purchase order.
1.2 Work Included
1.2.1.1 Furnish shop pipe spool sheets or extended spool sheets or
detailed drawings when specifically required by the purchase
order.
1.2.1.2 Furnish materials as required by the purchase order including
pipe, fittings, flanges, and welding materials required for
fabrication.
1.2.1.3 Fabricate pipe spools as follows:
1.2.1.3.1 Fabricate pipe spools including the installation of fittings,
nozzles, thermowell connections, radiographic access
holes/bosses, breather holes when required, and the preparation
of field welding ends.
1.2.1.3.2 Fabricate dual containment piping spools, and offset piping
assemblies (Joggles) that are either dual wall or single wall
configurations.
1.2.1.5 Supply and install integral structural attachments and supports as
shown on piping isometric drawings, orthographic drawings,
and/or detailed support drawings.
1.2.1.6 Perform post-weld heat treatment (PWHT) as required.
1.2.1.7 Perform all required testing and examinations.
1.2.1.8 Perform all required cleaning, lining, preservation, and shipping
preparation.
1.2.1.9 Chemically clean and/or pickle piping where indicated on the
design drawings and/or the piping material class.
1.2.1.10 Mark pipe spools with identification numbers in accordance with
the identification numbers shown on the piping isometric
drawings, orthographic drawings, or other instructions furnished
by the Buyer.
1.2.1.11 Furnish all required documentation.
1.2.1.12 Package fabricated spools and associated materials, with packing
lists, for delivery to the jobsite.
1.2.1.13 Apply color coding for material lay down purposes when
required by the purchase order.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility
Atmospheric Process Vessels
Exhibit 5, Page 5-2
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
1.2.1.14 Perform Positive Material Identification (PMI) on completed
fabrication in accordance with specification Exhibit 1, Positive
Material Identification (PMI) for Shop Fabrication, and as
required by Section 2.1.5. PMI is not to be performed on Buyer-
furnished valves unless otherwise stated in the purchase order.
Refer to Section 2.1.5.
1.2.1.15 Perform hydrostatic testing of fabricated spools when
specifically required by contract documents using Buyer
approved test procedures.
1.2.1.16 Perform pneumatic testing of fabricated spools when specifically
required by contract documents using Buyer approved test
procedures.
1.2.1.18 Installing fusion-bonded epoxies for linings is within a Supplier's
scope of supply when called for in the purchase order.
1.3 Related Work Not
Included
1.3.1 The following items are not included in the Supplier's scope of
work unless otherwise specified:
1.3.1.2 Furnishing and installing pipe supports (except as noted in
Section 1.2.1.5).
1.3.1.3 Furnishing of cast or ductile iron pipe.
1.3.1.4 Furnishing thermowells.
1.3.1.5 Furnishing and installing flow nozzles and associated hardware.
1.3.1.6 Installing fabricated piping subassemblies in the field.
1.3.1.7 Furnishing and installing thermal insulation for piping.
1.3.1.8 Pressure testing of all piping, except as required by Sections
1.2.1.15 and 3.2.3 of this exhibit and the pressure test required
by the applicable ASTM or ASME material specification.
1.3.1.9 Design of piping and preparation of piping drawings (except
detailed spool drawings in accordance with Section 1.2.1.1).
1.3.1.10 Furnishing bolting materials, gaskets, insulating flange kits, or
backing rings required for field assembly.
1.3.1.11 Pipe wall thickness and branch reinforcement calculations.
1.4 Codes and Standards
1.4.1 ASME B31.3 1996, Process Piping, is the piping code for the
WTP Project.
When using ASTM material specifications for commercial
material (CM) items, any version more recent than the ASTM
version listed in Appendix E of ASME B31.3 1996 is acceptable.
A SDDR is not required for these commercial material (CM)
item ASTM material specification edition changes.
ASME materials identified in ASME Boiler & Pressure Vessel
Code, Section II Material Specifications as being identical to the
ASME B31.3, Appendix E listed ASTM Material Specifications,
for the year, alloy, type and / or grade, (if applicable), are
acceptable for use.
See Specification Exhibit 10 of 24590-BOF-3PS-MVSC-T0002,
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility
Atmospheric Process Vessels
Exhibit 5, Page 5-3
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Section 2.1 for ASTM Material Specifications table for
acceptable years.
1.4.1.1 The American Society of Mechanical Engineers (ASME)
ASME B 16.11- 1991 , Forged Fittings, Socket- Welding and
Threaded
ASME 16.25-1986, Buttwelding Ends
ASME B16.28-1986, Wrought Steel Buttwelding Short Radius
Elbows and Returns
ASME B16.36-1988, Orifice Flanges
ASME B16.47-1990, Large Diameter Steel Flanges NPS 26
through NPS 60
ASME B16.5-1988, Pipe Flanges and Flanged Fittings NPS 1/2
through NPS 24 Metric/Inches
ASME B16.9-1986, Factory-Made Wrought Buttwelding
Fittings
ASME B36.10M-1985, Welded and Seamless Wrought Steel
Pipe
ASME B36.19M-1985, Stainless Steel Pipe
1.4.1.2 ASME Boiler and Pressure Vessel Code (B & PV)
ASME B & PV Code Section V- latest edition, Nondestructive
Examination
ASME B & PV Code Section VIII, Division 1, latest edition,
Rules for Construction of Pressure Vessels
ASME B & PV Code Section IX- latest edition, Welding and
Brazing Qualifications
1.4.1.3 American Society for Testing and Materials (ASTM) Material
Specifications
For ASTM material designations, refer to Exhibit 10, Technical
Supply Conditions for Pipe, Fittings, and Flanges.
1.4.1.4 Pipe Fabrication Institute (PFI) Standards
ES-7 - 1962 (R1984), Minimum Length and Spacing for Welded
Nozzles
1.4.1.5 Manufacturers Standardization Society
MSS SP-25-1978 (R1988), Standard Marking System for Valves,
Fittings, Flanges, and Unions
MSS SP-83-1987, Class 3000 Steel Pipe Unions Socket Welding
and Threaded
MSS SP-95-1986 (R1991), Swaged Nipples and Bull Plugs
MSS SP-97-1987, Integrally Reinforced Forged Branch Outlet
Fittings
1.4.2 Other Standards The following standards are not reference standards of ASME
B31.3, 1996, but are acceptable for use to facilitate ASME B31.3
piping fabrication, or are used for pipe fabrication that is not
within the scope of ASME B31.3.
1.4.2.1 Pipe Fabrication Institute (PFI) Standards
ES - 3, Fabricating Tolerance
ES - 5, Cleaning of Fabricated Piping
ES - 24, Pipe Bending Methods, Tolerances, Process, and
Material Requirements
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility
Atmospheric Process Vessels
Exhibit 5, Page 5-4
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
ES - 31 , Standard for Protection of Ends of Fabricated Piping
Assemblies
1.4.2.2 International Association of Plumbing & Mechanical Officials
Uniform Plumbing Code (UPC), 1997 Edition
1.5 Reference Documents
and Drawings
1.5.2 Exhibit 3 of 24590-BOF-3PS-MVSC-T0002, Cold Bending of
Pipe
1.5.3 Exhibit 4 of 24590-BOF-3PS-MVSC-T0002 , General Welding
and NDE Requirements for Supplier Fabricated Piping
1.5.9 Exhibit 1 of 24590-BOF-3PS-MVSC-T0002, Positive Material
Identification (PM) for Shop Fabrication
1.5.11 24590-WTP-3PS-G000-T0003, Engineering Specification for
Packaging, Handling, and Storage Requirements
1.5.13 24590-WTP-PW-P30T-00002, WTP End Prep Detail for Field
Butt Welds
1.5.14 Exhibit 10 of 24590-BOF-3PS-MVSC-T0002, Technical Supply
Conditions for Pipe, Fittings, and Flanges
1.7 Cleaning
1.7.1 Cleaning
1.7.1.1 Perform cleaning after fabrication has been completed. Cleaned
piping shall be free of loose rust or mill scale, blisters, grease,
sand, oil, dirt, and other foreign materials.
1.7.1.2 Fabricated spools shall be cleaned in accordance with the
standard cleaning method described in PFI-ES-5.
1.7.1.3 Clean austenitic stainless steel, nickel alloy, and titanium piping
in a protected area that is free from airborne chloride
contamination. Prevent contamination from non-stainless steel,
non-nickel alloy or non-titanium particles such as machine chips,
grinding dust, weld spatter, and other debris during fabrication
by shielding or other suitable means.
1.7.1.4 Only austenitic stainless steel brushes not previously used on
other material may be used on austenitic stainless steel piping.
Stainless steel wire brushes that have not been used on other
materials shall be used to clean nickel alloy or titanium.
1.7.1.5 Where solvent is required to remove grease or oil from austenitic
stainless steel piping, acetone, or alcohol (ethyl, methyl, or
isopropyl) shall be used. Alternatively, a detergent flush may be
used in lieu of solvent cleaning with prior permission to proceed
from Buyer.
1.7.1.6 Final cleaning materials in contact with austenitic stainless steel
shall contain less than 200 ppm chlorides. If detergent cleaning
is used, rinse austenitic stainless steel with potable water having
no more than 100 ppm chloride content. After rinsing, the piping
shall be drained out completely such that no standing
pockets/puddles of water remain that may later concentrate by
evaporation. Removal of excess rinse water may be augmented
by swabbing, use of a "squeegee," or air blowing.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility
Atmospheric Process Vessels
Exhibit 5, Page 5-5
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
1.7.1.7 After cleaning, blow dry the interior surfaces of all piping with
clean, filtered, oil-free air.
1.8 Packaging, Storage,
Handling, and Protection
Packaging, handling, and storage of pipe spools are as list below.
These requirements are based on the applicable requirements
listed in Specification 24590-WTP-3PS-G000-T0003.
1.8.1 Sealing Openings
1.8.1.1 Comply with the minimum end protection requirements criteria
outlined in PFI-ES-31 to protect all openings and/or as required
in the purchase order. The Buyer must provide review and give
permission to proceed prior to use of each specific type of
desiccant material. Fabrications must be clearly marked
indicating desiccant inside.
1.8.1.2 Cover all pipe openings with metal, polyethylene, or nonmetallic
end caps, flange protectors, or plugs. Polyethylene or
nonmetallic end caps and plugs shall be friction fit, (e.g.,
Niagara series) or secured by other means. At a minimum, one of
the caps or plugs on each spool shall be provided with a 1/8-inch
max diameter vent hole to preclude the buildup of internal
pressure. Avoid placing the cap or plug with the vent hole on a
spool that is oriented in an upward, vertical position. Tape shall
not be used to secure end caps or plugs. Clamps used for
securing end caps, on stainless steel or alloy spools, shall be
made of stainless material.
1.8.2 Marking
1.8.2.2 Place paint markings so that paint is at least 4 inches away from
a surface to be welded.
1.8.2.3 Any marking material and packing tape used on stainless steel or
alloy material is required to be made from low chloride (less
than 200 ppm) and low sulfur (less than 400 ppm) type material.
The Supplier shall provide a chemical analysis report of the
marker/tape for each lot or typical representative sample. The
chemical analysis report shall be submitted for Buyer's review
and permission to proceed. A copy of the report is not required
with each shipment of pipe spools.
1.8.3 Protection During
Shipping
1.8.3.1 Block, strap, or otherwise hold pipe, fittings, and valves in
position and further separate them by dunnage as necessary to
prevent damage during shipment.
1.9 Submittals
1.9.2 Submit the following documents for Buyer's review and
permission to proceed as specifically noted in the purchase
order:
1.9.2.2 Pipe spool sheets/extended spool sheets/detailed drawings for
shop-fabricated spools
(including identification of shop welds), when specifically
required in the purchase order. Shop spool drawings and/or
extended spool sheets based on isometric drawings provided by
the Buyer may be generated by the Supplier. However, unless
otherwise noted in the purchase order, pipe spool
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility
Atmospheric Process Vessels
Exhibit 5, Page 5-6
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
sheets/extended spool sheets/detailed drawings are not required
to be submitted for review and permission to proceed. Final
Supplier Quality inspection will be in accordance with the
isometric or orthographic drawing, as applicable.
1.9.2.4 Welding/weld repair procedures and procedure qualification
records (WPS/PQR).
1.9.2.5 Nondestructive examination (NDE) procedures prepared in
accordance with the applicable code and/or standard, and ASME
Section V and NDE reports including all radiographs as
applicable to the purchase order and piping material class.
1.9.2.7 For components that are not coated, cleaning procedures only are
to be submitted.
1.9.2.9 Bending procedures and bend qualification records.
1.9.2.12 Wall thickness measurement procedure for pipe bends.
1.9.2.14 Inspection procedure.
1.9.2.15 Chemical analysis report for marking material and packing tape.
1.9.2.16 Each specific type of desiccant material.
1.9.2.17 Procedure for measuring minimum wall thickness for bulk pipe
and butt weld fittings. Submittal shall include Supplier's
inspection and sampling plan. The term "butt weld fitting"
includes elbows, tees, reducers, caps, laterals, crosses, and
swages; however, it excludes, pipe nipples, flanges, socket weld
fittings, and integrally reinforced fittings.
1.9.3 The following documentation shall be submitted for each spool
as appropriate, with the spool shipment:
1.9.3.1 Pipe spool sheets/extended spool sheets/detailed drawings (as
applicable) with heat numbers of piping and pressure containing
parts or items.
1.9.3.2 Material test reports (MTRs) shall be submitted for each pipe
spool shipment for all metallic pipe spool and weld filler
materials. This is not applicable to Buyer supplied valve and /or
components.
1.9.3.4 NDE results (including volumetric, surface, and visual
examination results, as applicable) shall be documented and
forwarded with the pipe spool shipment. CM pipe spools outside
the HLW and PTF require a Certificate of Conformance (C of C)
certifying the NDE was performed in accordance with the
applicable codes and the test results were acceptable.
1.9.3.5 Pressure test results for fabricated piping, as applicable. CM pipe
spools require a Certificate of Conformance (C of C) from the
vendor certifying the pressure test was performed in accordance
with the applicable codes and the test results were acceptable.
1.9.3.7 Wall thickness measurement reports. Wall thickness
measurement applies to pipe bends, piping, bulk piping, and butt
weld fittings. The wall thickness reports are to be submitted for
these components for each heat/lot used for spool fabrication. In
addition, the applicable bulk pipe and butt weld fitting wall
thickness report is to be linked to every pipe and fitting on each
extended spool sheet or referenced on each extended spool sheet
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility
Atmospheric Process Vessels
Exhibit 5, Page 5-7
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
where that heat/lot of pipe or butt weld fittings has been used.
The term "butt weld fitting" includes elbows, tees, reducers,
caps, laterals, crosses, and swages; however, it excludes pipe
nipples, flanges, socket weld fittings, and integrally reinforced
fittings.
1.9.3.8 Record of any major weld repairs. A major weld repair is when
the depth of repair encroaches on specified minimum wall
thickness which is 87 1/2% of generally published specification
or standard nominal wall thickness. CM pipe spools require a C
of C from the vendor certifying a major repair was performed
and accepted in accordance with the applicable Buyer reviewed
procedure where the Supplier has been granted permission to
proceed. The C of C shall identify the spool piece mark and the
work performed.
Per Section 2.1.9, base metal repairs using welding shall not be
performed.
2 Products
2.1 Materials
2.1.1 General
2.1.1.1 All materials shall conform to the specified material
specification and the applicable code. All materials shall be new
and traceable to the respective MTRs.
2.1.1.1.2 For CM piping, outside BC or HtR areas, identify material by the
specific ASTM or ASME material specification number and
grade or type on shop spool drawings and extended spool sheets
(as applicable), along with heat number or heat number code
applied to or maintained on the pipe, traceable to the MTR.
2.1.1.1.3 Weld filler metal MTR/CMTR requirements are as listed in
Exhibit 4 of 24590-BOF-3PS-MVSC-T0002, General Welding
and NDE Requirements for Supplier Fabricated Piping.
2.1.1.2 Unless otherwise identified on piping design drawings, all
materials shall conform to the piping material classes for the
pipe class, except as allowed by specification Exhibit 10 of
24590-BOF-3PS-MVSC-T0002 and as specified below.
Seamless pipe and fittings, if available, are preferred in all cases.
2.1.1.2.1 Where material is specified as triple stamped, seamless
A106/A53/API 5L Grade B, the following single stamped
materials are acceptable:
(a) A 106 Grade B
(b) Seamless A53 Grade B
(c) Seamless API 5L Grade B
2.1.1.2.2 Where material is specified as double stamped, seam welded
A53/API 5L Grade B, the following single stamped materials
and/or triple stamped material are acceptable:
(a) Seamwelded A53 Grade B
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility
Atmospheric Process Vessels
Exhibit 5, Page 5-8
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
(b) Seamwelded API 5L Grade B
(c) Seamless A53/A106/API 5L Grade B
2.1.1.2.3 Where material is specified as dual grade Type 316/316L
stainless steel, a single grade Type 316L is acceptable.
2.1.1.2.4 Where material is specified as dual grade Type 304/304L
stainless steel, a single grade Type 304L is acceptable.
2.1.1.2.5 Where the purchase order description specifies pipe to be
furnished "Beveled Both Ends," pipe furnished with "Plain
Ends" is acceptable.
2.1.1.2.6 Where the purchase order description specifies pipe is to be
furnished "Double Random Lengths," pipe furnished in "Single
Random Lengths" is not acceptable.
2.1.1.3 Individual line service class material will be identified on piping
design drawings by indicating the appropriate piping class. Stock
codes will generally be assigned for each item of shop material.
The supplier shall ensure that the stock code shown on the
isometric Bill of Material matches stock codes attached to or
inscribed on materials prior to their installation.
2.1.1.5 The Supplier shall purchase material based on the Buyer stock
code's "long" or "purchase" description. The Buyer's short
description shall not be used for purchasing material.
2.1.2 Material
Traceability
2.1.2.1 Material traceability (such as identification of the item to
applicable material specification, heat, batch, lot, part, or serial
number or specified inspection, test, or other records) also
includes transferring material identification mark(s) prior to
subdividing material for all piping material. Traceability is being
able to trace the piping material to the applicable MTR. All
piping material, regardless of quality level, requires traceability.
2.1.2.2 As a minimum, individual spools shall have a pipe spool sheet,
extended spool sheet. or detailed drawing that reflects the heat
number of pressure containing items. Heat numbers and general
PMI locations of piping and pressure containing parts or items
shall be noted on the pipe spool sheet, extended spool sheet, or
detailed drawing for material traceability. A pipe spool sheet,
extended spool sheet, or detailed drawing may be defined as the
actual fabrication detail drawing, Bill of Materials, and/or
traveling data table for that spool piece. Second sheets, if used,
that provide spool material heat number information that is not
shown on the pipe spool sheet, extended spool sheet or detailed
drawing shall list the pipe spool number in order to maintain
traceability. These sheets/drawings shall accompany each
shipment of fabricated spools.
2.1.5 Positive Material
Identification (PMI)
Identification (PMI) tests in accordance with Exhibit 1 of 24590-
BOF-3PS-MVSC-T0002. The Supplier shall submit their PMI
test procedure for Buyer's review and permission to proceed.
2.1.6 Material
Commitment
The Supplier shall submit to the Buyer a complete itemized
listing of all materials purchased or reserved from the Supplier's
inventory for each project. The Supplier shall also provide, upon
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility
Atmospheric Process Vessels
Exhibit 5, Page 5-9
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
request, the current status of pre-bought or Buyer-furnished
material.
2.1.7 Material
Substitutions
All materials shall be in accordance with the Buyer-furnished
drawings, the purchase order, and specifications, unless written
permission to proceed is granted by the Buyer via the SDDR in
accordance with the purchase order requirement.
2.1.8 Material
Identification and
Marking
2.1.8.1 All materials shall be marked with the information and using
marking materials required by the specific ASTM or ASME
material specification.
2.1.8.2 Labeling with a marking pen on stainless steel and nickel based
alloy material shall be done by any permanent method that will
neither result in harmful contamination or sharp discontinuities,
nor infringe upon the minimum wall thickness. All marking
materials other than material manufacturer's marks shall be of
the low chloride (less than 200 ppm) and low sulfur (less than
400 ppm) type. It is acceptable to use a rounded, low stress,
vibro-etch tool for this marking.
2.1.8.3 Weld identification symbols must be recorded on detailed spool
sheets and extended spool sheets (as applicable) with a cross-
reference to any NDE report numbers.
2.1.8.4 Any piece of material not readily identifiable during fabrication
shall be rejected, including other components welded thereto.
2.1.9 Damaged Materials
2.1.9.1 Materials that have been damaged, gouged, or found to have
defects affecting their form, fit, function, or encroaching on
minimum wall thickness, shall not be used. Minor surface marks
may be dressed, provided that the minimum wall thickness is not
encroached upon after considering the manufacturing tolerances
defined in the appropriate material or technical specification.
Raised metal shall be blended into surrounding base metal. Base
material repair of damaged material, using welding shall not be
permitted.
2.1.9.2 Particular care must be taken with flange faces. Flanges are
required to meet the requirements of ASME B16.5. Flange
facing imperfections outside of those specifically discussed in
ASME B16.5, Pipe Flanges and Flanged Fittings NPS 1/2
though NPS 24 Metric/Inches, are not permitted. In addition,
should a scratch be deeper than the flange facing serrations, the
flange may be refaced, provided the height of the raised faced
portion of the flange is maintained. Weld repair of the damaged
flange facing is not permitted.
2.1.9.4 The Supplier shall not make any base metal material repairs
using welding.
3 Execution
3.1 Fabrication
3.1.1 General
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility
Atmospheric Process Vessels
Exhibit 5, Page 5-10
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
3.1.1.1 Fabricated piping shall be in accordance with Buyer-furnished
design drawings and specifications. Use welded joint
construction for all piping, except where otherwise called for on
the design drawings and the piping material class.
3.1.1.2 Make all welds full penetration butt welds except as permitted
otherwise for welded attachments, socket welds, slip-on flanges,
and joggle pipe jacket. Mark all welds with welder's unique
identification marks. It is acceptable to use a rounded, low stress,
vibro-etch tool for this marking.
3.1.1.3 All flanges shall be installed with the bolt holes straddling the
vertical centerline unless otherwise specified on the design
drawings.
3.1.1.4 All welds performed by a supplier shall be shown on vendor
spool sheets and extended spool sheets, as applicable. Additional
requirements are as follows:
3.1.1.4.1 Pipe lengths composed of two or more welded-together
segments of straight pipe at intervals of less than 6 feet are not
permitted, except as specified in Sections 3.1.1.4.2 and 3.1.1.4.3.
3.1.1.4.2 Shop butt welds not represented on the isometric drawing(s) may
be added to fabricate the spool(s) in accordance with the general
configuration portrayed on the isometric drawing(s), provided
the additional welds do not rest on pipe supports and provided
the additional weld is not within 2 feet of existing butt welds or
additional new butt welds. Bends shall not be replaced by elbows
without prior written concurrence from the Buyer. The minimum
required edge distance (D) between an integral attachment to the
pipe and pipe weld or other inline components is provided in the
table below. (The equation used to develop this table is √𝑅𝑚𝑡 . Rm = Mean Radius of the pipe and t = thickness of the pipe.)
3.1.1.4.3 Addition of butt welds is preferred over the addition of socket
welds, even in a socket welded system. However, socket welded
couplings may be added by the Supplier to socket welded piping
systems, provided the couplings are not located any closer than 2
feet from other welds, and provided the added couplings do not
rest on pipe supports.
--
Table 1 Minimum Required Edge Distance Between Field and Shop Welds
Nominal Pipe Size D
(inches) (inches)
3" and under l
3.5" to 6" 1 5/8
8" to 12" 2 3/4
14" tol 8" 3 7/8
20" to 24" 5 1/8
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility
Atmospheric Process Vessels
Exhibit 5, Page 5-11
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
3.1.1.4.4 It is acceptable for the Supplier to add a socket welded coupling
to one side of the field weld joint when just a field weld (without
a coupling) is shown on an Isometric for a socket welded system.
3.1.1.9 Certain Buyer isometric drawings are dimensioned to the
centerline of a Buyer field supplied and installed welded
component between the two spools. For these isometrics the
Supplier shall fabricate that portion of the spool length to the
centerline of that component. Each of these spools shall have a
plain end at the center point of the Buyer field installed welded
component. Buyer is responsible for cutting and end preparation
(as required) for field installation of this Buyer supplied
component. These plain ends are not field fit up welds (FFW).
As such do not require an additional 6" of pipe length.
3.1.2 Weld Joint
Preparation
3.1.2.1 Unless otherwise noted on the design drawings, field butt weld
end preparations shall be in accordance with drawing 24590-
WTP-PW-P30T-00001.
3.1.2.2 Do not use backing rings.
3.1.3 Bending Pipe bending shall be in accordance with document Exhibit 3 of
24590-BOF-3PS-MVSC-T0002, except as follows:
3.1.3.1 Refer to standard PFI ES-24, Paragraph 5.1, for tolerances
associated with specific bend angles as shown on project
isometric drawings. Also, refer to PFI-ES-24, Paragraph 6 for
form tolerances related to buckling.
3.1.4 Dimensional
Tolerances, Except For
Pipe Bends
Unless otherwise indicated on the design drawing, do not exceed
the dimensional tolerances of PFI-ES-3 for fabricated piping
assemblies.
3.1.5 Welding Processes Use welding processes in accordance with document Exhibit 4 of
24590-BOF-3PS-MVSC-T0002 and the applicable code and/or
standard.
3.1.6 Welding Procedures
and Welder
Qualifications
3.1.6.1 Welding shall be performed by qualified welders in accordance
with welding procedures prepared and qualified in accordance
with the applicable code and/or standard, and ASME Section IX
using procedures reviewed by the Buyer and after receiving
permission to proceed.
3.1.6.2 Type 316L or Type 316LSi weld filler metal may be used for
welding Type 304L stainless steel.
3.1.7 Flanges Furnish flanges for flanged connections in accordance with the
piping material classes and as shown on design drawings.
3.1.7.1 All slip-on flanges shall be double welded in accordance with
paragraph 328.5.2 of ASME B31.3 unless directed otherwise by
design document(s).
3.1.8 Branch Connections
3.1.8.1 Branch connections shall be in accordance with the applicable
piping material class (es).
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility
Atmospheric Process Vessels
Exhibit 5, Page 5-12
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
3.1.8.2 Threaded branch fittings on piping spools that have been hot-dip
galvanized shall have the threads "chased" after dipping to
ensure that threads are free from excess galvanizing materials
that would prevent the threaded joints from being made up upon
installation.
3.1.9 Orifice Runs Straight pipe orifice runs shall not contain welds, except at
flanges. Pipe ends at orifice flanges shall be machine cut
perpendicular to the pipe axis. Welds at orifice flanges shall be
ground smooth inside. Pipe tap connections (if required) are to
be drilled through the pipe wall and shall be smooth inside.
Orifice flanges shall be drilled and tapped for jack screws. Buyer
supplied drawings show the orientation of orifice flange taps and
the locations of pipe taps. Unused orifice flange taps shall be
supplied with appropriate plugs.
3.1.11 Rework of
Fabricated Spools
3.1.11.1 Reworked spools being shipped to the jobsite shall be provided
with a Certificate of Conformance (C of C) stating the spools
identified are the same spool number(s) originally delivered and
received. The C of C shall state that the re-worked spools are in
strict accordance and fully comply with the purchase order and
all procedures and specifications. The C of C shall also state the
re-work performed on each spool.
If additional materials are added, or if additional documentation
is provided (NDE reports, MTRs, etc.) a complete
documentation package for that spool shall be furnished.
3.2 Inspection and
Testing
3.2.1 General
3.2.1.1 The Supplier is responsible for nondestructive examination and
testing of piping furnished under this exhibit.
3.2.1.2 All examination, inspection, and testing shall be in accordance
with this exhibit and other governing codes and standards, as
applicable. This includes nondestructive examination of the
piping spools in accordance with the requirements for Normal
Fluid Service piping in ASME B31.3-96.
3.2.1.3 Buyer's representative shall be provided free access to the
Supplier's and Supplier's subcontractor's or Supplier's facilities,
to witness, inspect, and report progress of work.
3.2.1.4 Note: No sub-supplier shall perform NDE work without prior
submittal of the sub-supplier's NDE procedure and Buyer's
review and permission to proceed.
3.2.2 Examination of
Fabrication Welds
3.2.2.1 Examine all completed pressure boundary welds in accordance
with the ASME B31.3-96 and/or standard, including the
requirements listed below, as applicable. Weld repair shall be
examined according to the requirements used for the original
weld.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility
Atmospheric Process Vessels
Exhibit 5, Page 5-13
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
3.2.2.2 Perform and evaluate examinations in accordance with
procedures and acceptance standards prepared in accordance
with the ASME B31.3-96 and/or standard, and the ASME Boiler
& Pressure Vessel Code, Section V.
3.2.2.4 Weld NDE and
Inspection Requirements
The following are the NDE and inspection requirements for
piping welds. These requirements are summarized in Appendix
A. The acceptance criteria are as listed in ASME B31.3, Table
341.3.2, for Normal Fluid Service Conditions with the following
additions:
3.2.2.4.1 Where radiographic examination (RT) is allowed or specified for
shop welds, the radiographic acceptance criteria for Normal
Fluid Service apply, except that incomplete penetration shall not
be permitted.
3.2.2.4.2 Where liquid penetrant examination (PT) or magnetic particle
examination (MT) is allowed or specified, no cracks shall be
permitted.
3.2.2.4.3 All shop girth welds require full visual examination in
accordance with the requirements of ASME B31.3-1996, para
341.4.1 (a), and NDE examination in accordance with the
requirements of ASME B31.3-1996, para 341.4.1 (b).
3.2.2.4.6 Fillet welds including socket welds, integral support welds, and
non pressure and non load bearing piping attachment welds (e.g.,
cathodic protection clips) welds require NDE in accordance with
ASME B31.3, para 341.4.1.
3.2.2.4.7 Integrally reinforced forged branch fitting connection welds,
welded to the main piping run shall be examined in accordance
with the requirements of ASME B31.3, para 341.4.1. The girth
weld that connects the fitting to the branch pipe run shall be
examined in accordance with requirements of ASME B31.3,
para 341.4.1.
3.2.2.4.8 Full penetration welded stub-in lateral branch connection fittings
used on gravity drain piping require 100% VT and 100% PT of
final pass only
3.2.3 Pressure Testing
3.2.3.1 Do not perform hydrostatic test on fabricated piping assemblies
other than piping coated and wrapped in the Supplier's shop, and
other spools when designated by approved documents.
3.2.3.2 Perform pressure test of coated piping in accordance with the
applicable code prior to coating operations, unless the Buyer
opts to leave joints uncoated for inspection during field
hydrotest. Potable water shall be used for the pressure test
performed by the Supplier. When pressure testing stainless steel
piping, the test water shall not contain more than 200 ppm
halogen. The Supplier shall submit a pressure testing procedure
for Buyer's review and permission to proceed prior to performing
the test. The Supplier shall also include a record of the test result
as part of pipe spool documentation
3.2.3.3 Welding of integral supports shall be avoided in previously
hydrostatically or pneumatically tested piping. Buyer
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility
Atmospheric Process Vessels
Exhibit 5, Page 5-14
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Engineering shall be consulted immediately when this situation
occurs.
3.2.3.4 After installation, all fabricated assemblies will be tested by
others in accordance with the applicable code. Should any defect
be detected during field testing, the defect will be repaired by the
Buyer at Supplier's expense.
4 Configuration
Management
Configuration management is maintained by fabrication and
installation in accordance with approved drawings and
procedures. Fabrication and installation shall be performed in
accordance with approved documents. Where fabrication and
installation cannot be accomplished in accordance with approved
procedures and drawings, the Buyer shall be promptly notified
via a SDDR or other suitable means. Fabrication and installation
shall not proceed until a resolution is approved and proper
documentation is provided.
5 Documentation and
Submittals
Documentation is provided by approved procedures and
drawings. Any records generated by working to procedures and
drawings shall be submitted to the Buyer for logging and
issuance. Refer to section 1.9 for submittal details.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric Process Vessels
Exhibit 5, Page A-1
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Appendix A
Summary Table of Non-Destructive Examinations (NDE) of Pipe & Tubing Shop Welds
Table I Piping Weld Examination Requirements
SEE SECTIONS 2.1.4, 3.2.2.2, 3.2.2.3, 3.2.2.4 FOR APPLICABLE SHOP WELD NDE, INSPECTION, AND ACCEPTANCE CRITERIA RE UIRElVIENTS. 2. SEE NEXT SHEET FORNDE LEGEND AND TABLE FOOTNOTES.
Type of Weld .J,
All Girth and Miter Welds
All Longitudinal Seam Welds on Seamwelded Pipe and Fittings
Outer Pipe Shop Performed Longitudinal/Clam Shell Welds for Dual Contained Piping
Piping Ctib JBS IIJIG IJL lieu els ta ens 1
100% VT 5%RTor5%UT
See Note 2
NIA
Double Encased Pipe Joggle Assemblies (shop welds on both inner and NIA outer piping)
Sleeved Joggle Assemblies ( shop welds on inner piping only) NIA
All Pipe and Integral Attachment Fillet Shop Welds - including tbem1owell socket welds, integral support welds, non pressure & non load bearing piping attachment welds
All integrally reinforced forged branch fittings welded to main piping run.
Fu B811!lt'plplXg, M LOOJJ [(f e:m MEPIOG&CCM[ IB&[PJ€iSO& IAWOID'.hbd. !n Rnsnss Erarnhefa and r, ·a r r : r f I t sft th th ... 1001 mid mml p!Gs weld ts accepcaote. •
100% VT
100% VT
100%RT
100% VT 100% RT
100% VT
Dual Containment (outside BC or HtR areas)
Inner Piping
100% VT 100%RT
100% PT or 100%MT
100% VT 100% PT or 100%MT
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric Process Vessels
Exhibit 5, Page A-2
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Legend: VT = Visual Examination per ASME B31.3 para 344.2
RT= Radiographic Examination per ASME B31.3 para 344.5 UT = tntrasonic Examination per ASME B3 I .3 para 344.6
LOO% VT 100%PT
100%VT 100% RT
Those requirements are specified
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 6, Page 6-1
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
EXHIBIT 6 | PRESSURE VESSEL DESIGN AND FABRICATION
Specification 24590-WTP-3PS-MV00-T0001, REVISION 5 was used as applicable to create the
following exhibit. Specification change notices (SCNs) have been evaluated and there are no
applicable SCNs. Incorporated SDDRs 24590-WTP-SDDR-MS-17-00111 and 24590-WTP-SDDR-
MS-17-00117.
Note: All References on this exhibit are inclusive to this exhibit only.
Specification Requirement
1 Scope
1.1 Project
Description and
Location
This exhibit is included in the Purchase Order, Material Requisition or in the scope of
work of subcontract packages. It defines the technical requirements for the design,
fabrication, and testing of pressure vessels for the Hanford Tank Waste Treatment and
Immobilization Plant (WTP) project located in the southeastern part of Washington
State.
1.2 Acronyms and
Definitions
1.2.2 Containment: Components that contain active process fluids inside the plant process
system. Refer to the MDS for the containment classification of components.
• Primary Confinement: The boundary within which the process fluids, gases, and
vapors are contained and confined during the plant process operation. In this
document, the entire process vessel and nozzle walls are generally referred to as the
Primary Confinement.
• Primary Containment: The part of the Primary Confinement that is in contact with
the process fluid. This is typically the wetted portion of the vessel wall below the top
of the overflow.
• Auxiliary Containment: This term is used in this document to identify the portion of
a Primary Confinement that is not subject to a static pressure head of liquid but may
be in contact with splashing liquid, vapor, or gases. This is typically the vessel
components above the prescribed high operating liquid level.
• Secondary Containment: The boundary that will contain process liquid if the
Primary Containment is breached. This boundary will not normally be in contact with
the process liquid. Typically, this is the cell liner or wall structure of the facility.
1.2.7 ECDS: The section of the MDS titled Equipment Cyclic Data Sheet. If components of
a vessel are subjected to cyclic loads, those loads will be detailed in the ECDS.
2 Applicable
Documents
2.1 General
2.1.1 Work shall be in accordance with the referenced codes, standards, and documents
listed below, which are integral parts of this specification.
2.1.2 When specific chapters, sections, parts, or paragraphs are listed following a code,
industry standard, or reference document, only those chapters, sections, parts, or
paragraphs of the document are applicable and shall be applied. When more than one
code, standard, or referenced document covers the same topic, the requirements for all
must be met with the most stringent governing.
2.2 Codes and
Industry Standards
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 6, Page 6-2
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
2.2.1 The Seller shall apply the latest issue, including addenda, at the time of request for
quote or award as applicable for the following codes and industry standards with
exceptions as noted.
2.2.1.1 ASME Section VIII, Division 1 , Rules for Construction of Pressure Vessels,
American Society of Mechanical Engineers
2.2.1.2 ASME Section II, Materials, American Society of Mechanical Engineers
Use of later version of the code or standard directly comparable and equivalent in
approach, Buyer approval is NOT required. If the later version of the code or standard
is not directly comparable and essentially equivalent use of the later version requires
AI's approval
2.2.1.3 ASME Section V, Nondestructive Examination, American Society of Mechanical
Engineers
2.2.1.4 NBIC, National Board Inspection Code, National Board of Boiler and Pressure Vessel
Inspectors
2.2.1.5 WRC-107, Local Stresses in Spherical and Cylindrical Shells due to External Loading,
Welding Research Council
2.2.1.6 WRC-297, Local Stresses in Cylindrical Shells due to External Loadings on
Nozzles— Supplement to WRC Bulletin No. 107, Welding Research Council
2.2.1.7 PFI Standard ES-24, Pipe Bending Methods, Tolerances, Process and Mechanical
Requirements, Pipe Fabrication Institute, Engineering and Fabrication Standard
2.2.1.8 ASME Section VIII, Division 2, Rules for Construction of Pressure Vessels -
Alternative Rules, American Society of Mechanical Engineers, (Note: Code year not
later than 2004 Edition with 2005 and 2006 Addenda).
2.2.1.9 ASME B31.3, Process Piping, 1996, American Society of Mechanical Engineers
2.2.1.10 AISC M016, ASD Manual of Steel Construction, 9th Edition, American Institute of
Steel Construction
2.2.1.11 Deleted.
2.2.1.12 SNT-TC-1A, Recommended Practice No. SNT-TC-1A, American Society for
Nondestructive Testing, Inc. (Note: Refer to the Quality Assurance Program
Requirements Data Sheet in the Purchase Order for acceptable editions).
2.2.1.13 ANSI/AWS D1.1, D1.6 Structural Welding Code
2.2.2 The Seller shall apply the issue and addenda as referenced in Table U-3 of ASME
Section VIII, Division 1 for the following codes and industry standards:
2.2.2.1 ASME B16.5, Pipe Flanges and Flange Fittings NPS 1/2 through NPS 24
2.2.2.2 ASME B16.47, Large Diameter Steel Flanges NPS 26 through NPS 60
2.2.3 The Seller shall apply the issue and addenda as stated for the following codes and
industry standards:
2.2.3.1 ASCE 7-98, Minimum Design Loads for Buildings and Other Structures, American
Society of Civil Engineers
2.3 Related
Documents
Other project specifications, standards, and standard details as listed or referenced in
Section 2 of the purchase order shall be used as applicable for the design and
fabrication of the vessels.
2.4 Project Documents
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 6, Page 6-3
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
2.4.1 Exhibit 7 of 24590-BOF-3PS-MVSC-T0002, Seismic Qualification Criteria for
Pressure Vessels
2.4.2 Exhibit 8 of 24590-BOF-3PS-MVSC-T0002, Pressure Vessel Fatigue Analysis
2.4.3 Exhibit 1 of 24590-BOF-3PS-MVSC-T0002, Positive Material Identification (PMI)
for Shop Fabrication
2.4.4 24590-WTP-MV-M59T-00002 , Pressure Vessel Tolerances Standard Details
2.4.5 24590-WTP-3PS-MVB2-T0001, Engineering Specification for Welding of Pressure
Vessels, Heat Exchangers and Boilers
2.4.7 24590-WTP-3PS-G000-T0003, Engineering Specification for Packaging, Handling
and Storage Requirements
2.4.8 Exhibit 2 of 24590-BOF-3PS-MVSC-T0002, Structural Design Loads for Seismic
Category IV Equipment and Tanks
3 Design
Requirements
3.1 Basic
Requirements
3.1.1 Unless otherwise specified, all vessels shall be designed and fabricated in accordance
with ASME Section VIII, Division 1, any additional requirements of this exhibit,
MDS, and the referenced Drawings.
3.1.3 Seller shall consider design details and material thickness shown on Drawings and
MDS as the minimum requirements.
3.1.4 Seller shall not scale Drawings
3.2 Loadings
3.2.1 Seismic analysis shall be performed per the requirements of Exhibit 7 of 24590-BOF-
3PS-MVSC-T0002.
3.2.2 If wind or snow loadings are specified on the MDS, the design for such loadings shall
be based on the requirements of the ASCE 7, using the indicated wind and snow
loading parameters.
3.2.3 If the MDS contains an ECDS, the Seller shall analyze for fatigue per the
requirements detailed in the Exhibit 8 of 24590-BOF-3PS-MVSC-T0002. Seismic
loadings shall not be considered when performing a fatigue analysis.
3.2.4 Unless indicated otherwise on the MDS or Drawings, the Seller shall design the
vessels to support process liquid filled to the top of the overflow.
3.3 Corrosion/Erosion
Allowance
3.3.1 Corrosion allowance is specified on the MDS and shall be applied to each surface
exposed to process vapor or liquid. Internal piping shall have the specified corrosion
allowance applied to both internal and external surfaces.
3.3.2 Unless otherwise specified, corrosion allowance shall not be applied to external vessel
surfaces.
3.3.3 Erosion allowances, where required, will be specified in the MDS.
3.4 Heads The Seller shall use head shapes as specified on the vessel drawing. Deviations from
this profile may be considered for economic, space or fabrication concerns. Any
change, however, requires the approval of the Buyer via SDDR.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 6, Page 6-4
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
3.5 Supports and
Anchors
3.5.1 Seller shall provide vessel supports as illustrated on the Drawings.
3.5.2 Supports and anchors shall be designed to secure the buoyant vessel in case the vessel
is empty and submerged to the level indicated in the MDS.
3.5.3 Criteria Detail design of vessel supports shall be in accordance with the recommendation of
ASME Section VIII, Division 1, Appendix G, except as noted below.
3.5.3.3 SC-IV stainless steel vessel supports are to be designed in accordance with Exhibit 2
of 24590-BOF-3PS-MVSC-T0002, Engineering Specification for Structural Design
Loads for Seismic Category IV Equipment and Tanks and 24590-WTP-DC-ST-01-
001 as applicable for SC-IV vessels.
3.6 Nozzles and
Manways
3.6.1 Nozzle wall thickness shall be per ASME Section VIII, Division 1 and at least that
specified on the Drawings. Seller shall understand that minimum nozzle thicknesses
indicated on the Drawings may not support the nozzle loading requirements listed in
Appendix A.
3.6.2 Nozzles and manways and their reinforcements located on the head shall be located
fully within the crown region of the head unless noted otherwise on the Drawing.
3.6.3 All nozzles shall be set-in type or through type with full penetration welds. All
nozzles, which are flush with the inside surface of the vessel, shall be rounded to 1/8
inch minimum radius as shown below. Nozzles for pressure relief devices, vents, and
drainage shall be flush with the inside surface of the vessel. Nozzles with internal
projection in primary containment shall have an additional fillet weld between the
internal projection and the inside surface of the shell or head.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 6, Page 6-5
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
3.6.4 The following illustrates acceptable and unacceptable nozzle configurations and
welding:
3.6.5 Flange boltholes shall straddle natural vessel centerlines unless otherwise specified.
3.7 Nozzle Loading
3.7.1 Unless otherwise specified, Seller shall design nozzles for the minimum nozzle design
loads listed in the applicable table of Appendix A for the connected pipe size.
Nozzles/shell on vessels are to be designed according to the methods of WRC-107,
WRC-297 as a minimum.
Set-In Nonie w h Full Penetration Weld
R,~us l/r7"'1
,do,lh,11
/
NomeN!d<
0111 Ml-In ~I ,_,11.,,,Wololl 1or r11.,,.s.n.o
R l)oltfedfor
NcuJt•"' Poow, Con1111nmtt1r
-t- -N Head cw Shall
Through Noute with Full Penetration Weld
Nou!e: Ntd.
C<,nca,e
Pr f.iltt V. Id
Hudo1Shtltl
Optinn•I Thrnugh Nnnl lnr F•tl911 • rvlr~
Unacceptable 01..zle Connectio ns
Set-on Nozzle with Full Penetration Weld Through Nozzle with Double Fillet Weld
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 6, Page 6-6
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
3.7.2 Appendix A lists minimum design nozzle loads by nozzle size, connecting pipe
material, and Seismic Category for weight, seismic, and thermal expansion cases. The
coordinate system conforms to the 'right hand rule'. Loads provided in Appendix A do
not have a sign convention; Seller must ensure that the direction of load application
provides the most conservative stresses at the nozzle to shell or head junction. The Y-
axis is vertical and in the direction of gravity regardless of the orientation of the
nozzle. Loads act at the juncture of the nozzle and shell.
3.7.3 Nozzle load combinations to be considered for Primary and Secondary Stress in the
design shall be:
Weight + Seismic + Operating Pressure + Thermal Load (Appendix A)
Note: Thermal Loads listed in Appendix A are from the loads resulting from the
restrained free end movement of the attached pipe and are considered as primary loads
per paragraph 4-138 of Appendix 4 of ASME VIII Division 2.
With regard to the radial load, the internal pressure shall not be used to oppose the
compressive stress due to the force acting inwards; for this load condition a null
pressure condition is to be considered to exist.
Nozzle load combinations to be considered for Secondary Stress in the design shall be:
Weight + Operating Pressure + Thermal Load (Appendix A) + General Thermal (per
code definition)
3.7.4 The nozzle loads provided are for the piping connected to the external nozzle. If a
nozzle projects and is loaded internally to the vessel, design the nozzle for the sum of
the internal and external loads.
3.7.5
The nozzle loads due to thermal expansion listed in Appendix A are estimated based
on the operating temperature of 350 °F. If the maximum operating temperature of the
attached pipe is less than 350 °F, the nozzle thermal loads may be reduced by a scale
factor of the absolute value.
Where X is the maximum vessel operating temperature of the attached pipe.
3.8 Nozzle
Reinforcement
3.8.1 When required, suitable nozzle reinforcements must be provided. Reinforcement
methods are limited depending on the assigned Design Level and cell designation.
Refer to Section 6 for allowable reinforcement methods. If the wall thickness of the
nozzle neck is greater than that of the connecting piping, the requirements of ASME
Section VIII, Division 1, and Figure UW-13.4 shall be satisfied.
3.8.2 Nozzle reinforcing pads, where permitted, shall have one-piece construction (not
segments). Nozzle insert plates (integral pads) shall be in accordance with ASME
Section VIII with a 3 to 1 taper.
f I X - 70 I 13 0-70
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 6, Page 6-7
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
3.8.3 For external nozzle reinforcing pads, the pad thickness shall not exceed 1.5 times the
thickness of the penetrated shell. To meet nozzle loading requirements, pad diameter
may exceed the limits of reinforcement per ASME Section VIII, Division 1. Pad width
shall be at least 2 inches but shall not exceed ten times the thickness of the pad. Each
pad shall have single 1/8 inch nominal pipe size (NPT) telltale hole for testing
purposes. On completion of all fabrication activities, the hole shall be fitted loosely
with a screwed plug of the same material as the reinforcement plate.
3.8.4
The following illustrates acceptable reinforcement practices for nozzles irrespective of
Design Level:
3.8.5 Nozzles on Commercial Grade may use external reinforcing pads (See figure below).
As a warning, the nozzle loads specified in Appendix A may exceed the practical use
of repads. In such cases, the Seller should consider locally increasing the thickness of
the shell or head with an insert plate or increasing the nozzle neck thickness as
required. The following illustrates acceptable reinforcing practices with full
penetration welds for nozzles on Commercial Grade vessels.
3.8.6 Material used for nozzle reinforcement shall be the same as the parent vessel unless
approved by the Buyer as stated on the MDS.
118 inch NPT Telltale Hole
Insert Plate
Nozzle Reinforcement Methods for All Design Levels
Increase Nozzle Neck Thickness
Increase Nozzle Neck Thickness
Insert Plate
Nozzle Reinforcement Methods Only for Commercial Grade Vessels
Not Located in a Black Cell
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 6, Page 6-8
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
3.8.7 Structural reinforcing elements such as reinforcing rings or pads (integral or non-
integral) can be used as necessary to accommodate new design load combinations on
fabricated and partially fabricated vessels. Any butt-weld seams to be covered by the
pads shall be ground flush and radiographically examined, in accordance with ASME
Section VIII, Division 1, subdivision UW-51, before the reinforcing pads are welded
in place. Reinforcing pads may be formed to the required shape by any process that
will not unduly impair the physical properties of the material. Reinforcing pads shall
be fitted to conform to the curvature of shell, head, or other surfaces to which they are
attached to minimize flat spots and horizontal surfaces that could collect solids. Edges
of non-integral pads shall be tapered 3 to 1 minimum to match the height of the legs of
the attaching fillet welds. The fillet welds shall fully seal the dead space between the
pad and the shell, head, or other surfaces to which the pad is attached.
3.9 Internal
Components and
Supports
3.9.1 Deleted.
3.9.1.1 Piping Internal to the Vessel
Piping internal to the vessel is to be designed in accordance with ASME B31.3-1996,
Process Piping with following modification:
In Table D300, the description of welding tee per ASME B16.9 shall be revised so it
is consistent with that shown in Table D300 of ASME B31.3-2002:
3.9.1.4 SC-IV stainless steel support structures within the vessel that support items such as the
internal piping or other internal components, that are away from the discontinuity shall
be designed in accordance with Exhibit 2 of 24590-BOF-3PS-MVSC-T0002,
Engineering Specification for Structural Design Loads for Seismic Category IV
Equipment and Tanks and 24590-WTP-DC-ST-01-001 as applicable for SC-IV
St rcss I ntcnsification Factor INote.s (2), (3)1
Flexibility Flexibility Factor Out-of- In-Plane Characteri
Description k Plane, i; stic, ketch io "
Welded tee per ASME 0.9 314 io + 114 J. l f
Same 816.9 I - as
[Notes (2), (4) , (6), (1 1 ), h2,,
,.2 ASME (13)] 831.3-
1996
ThL mean that for we lding tees per ASME B 16.9, note 11 in Table D300 is also changed to:
( 11 ) If r, ;c: I / 8D,. and?; ;c: I.Sf. a flexibili t character istic of 4.4 ¼ r, may be used.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 6, Page 6-9
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
vessels. The support at the discontinuity with the vessel is within the code pressure
boundary and shall be designed per ASME Section VIII.
3.9.3 Deleted.
3.9.4 Deleted.
3.9.5 If indicated on Drawings, the internal surface of the head or shell subjected to direct
impingement of process fluid shall be protected by a wear plate. See the MDS for the
wear plate material.
3.9.6 Internal process piping which opens to the vessel contents shall be designed for the
vessel design pressure and temperature or greater. Internal process piping which is
connected to equipment internal to the vessel, shall be designed to that internal
equipment design pressure and temperature.
3.10 External
Components and
Supports
3.10.1 If the MDS specifies insulation, the Seller shall provide and install insulation supports
per the Drawings.
3.10.2 Lifting and tailing lugs shall be provided and installed by the Seller per the Drawings.
The Seller may propose alternate designs and submit SDDR for Buyer approval prior
to detail design.
3.10.3 The Seller is responsible for determining the necessity of stiffening rings. The material
shall be 304/304L and attachment welds shall be continuous on both sides of the ring.
Reinforcement Pads for nozzles, guides etc., shall be 304/304L.
3.10.4 If specified on the Drawings, Seller shall provide and install support clips for piping or
platforms. The materials welded to the shell shall be 304/304L.
3.10.5 If indicated on the Drawings, Seller shall provide and install grounding lugs.
3.10.7 The base of the vertical vessel support skirt shall be marked, using a line of welding
bead, at the 0 degree orientation as shown on the Drawings.
3.10.8 If a separate ring beam support is specified on the vessel drawing, the top flange shall
be marked, using a line of welding bead, at the 0 degree orientation as shown on the
Drawings. Vendor shall include ring beam geometry in their vessel/skirt analysis and
shall provide forces and moments at the bottom of ring beam at embed
location/interface.
3.10.9 The external supports skirts, legs, saddle, lugs etc., shall be designed in accordance
with Exhibit 2 of 24590-BOF-3PS-MVSC-T0002, Engineering Specification for
Structural Design Loads for Seismic Category IV Equipment and Tanks and 24590-
WTP-DC-ST-01-001 as applicable for SC-IV vessels. The support at the discontinuity
and with vessel is within the code pressure boundary and shall be designed per ASME
Section VIII.
4 Materials
4.1 General
4.1.1 Materials shall be new and free from defects. Classification of fabrication materials
shall be in accordance with ASME Section II. The Seller shall furnish legible copies
of the mill test reports from the manufacturer for materials comprising the Primary
Confinement, internals, supports, and welded attachments. Other materials shall be
provided with certified statements that the material meets the requirements of ASME
Section II.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 6, Page 6-10
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
4.1.2 Material shall be furnished to the specification and grade shown on the MDS. The
fabricator shall not substitute materials without written approval from the Buyer.
4.1.3 Contact materials including marking materials, temperature indicating crayons,
adhesive backed and pressure sensitive tape, and barrier and wrap materials may be
used only under the following limits:
• The total halogen content shall not exceed 200 parts per million (PPM)
• The total sulfur content shall not exceed 400 PPM
• No intentionally added low melting point metals such as lead, zinc, copper, tin,
antimony, and mercury.
Anti spatter compounds shall not contain chlorine, fluorine, sulfur, mercury or other
low melting point metals.
Materials and residue shall be completely removed when no longer required. Cleaning
materials may be non-halogenated solvents or potable water containing no more than
50 PPM chloride. Contact materials shall be controlled and documented in accordance
with the Seller's inspection and test plan as approved by the Buyer.
4.1.4 Seller shall maintain a positive system of identification of materials used in the
fabrication of each vessel per Exhibit 1 of 24590-BOF-3PS-MVSC-T0002.
4.2 Pipe Fittings Pipe fittings shall conform to the appropriate ASME and ANSI standards for materials
and dimensions unless otherwise stated in the purchase order.
5 Fabrication
5.1 General
5.1.1 Seller shall, if necessary, provide temporary stiffening and jigging to prevent shell
distortion during fabrication, welding processes, heat treatment, hydrostatic testing, or
shipment.
5.1.2 Fabrication tolerances shall be in accordance with ASME Section VIII, Division 1 and
standard drawing 24590-WTP-MV-M59T-00001.
5.1.3 The sequence of fabrication shall be planned to permit maximum access to the internal
surfaces to enable examination of all welds.
5.1.4 Plates and pipes shall be cut to size and shape by machining, grinding, shearing,
plasma, laser, or water jet cutting. Plates, 3/8 inch thick and above, cut by shearing,
shall either be dye penetrant tested on the sheared edge or have 3/8 inch allowance left
on the edges which shall be removed by machining or grinding. All thickness of plate
or pipe cut by air plasma cutting shall have the edges dressed to a smooth, bright
finish. Material cut by the inert gas shielded plasma, laser or water jet process will not
require further dressing other than deburring. All lubricants, burrs, and debris shall be
removed after cutting.
5.1.5 All stamps used for identification reference markings shall be of the low stress type.
Stampings shall not be located near discontinuities.
5.1.6 If a butt welded seam is required between materials of different thickness, the thicker
material shall normally be machined on the side away from the process liquid.
Machining shall ensure a smooth finished profile with no sharp corners and shall be in
accordance with ASME Section VIII, Division 1 .
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 6, Page 6-11
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
5.1.7 When rolling any austenitic stainless plate, care shall be taken to prevent carbon
pickup or contamination of rolled material. The work area shall be free of carbon steel
grindings and general cleanliness shall be maintained to preclude carbon
contamination.
5.1.8 Only stainless steel brushes, clean iron-free sand, ceramic, or stainless steel grit shall
be used for cleaning stainless steel or nonferrous alloy surfaces. Cleaning tools or
materials shall not have been previously used on carbon steel.
5.1.9 Internal piping bends shall have a center line radius of four times the pipe nominal
diameter. In confined spaces, the centerline radius may be reduced to three times the
outside diameter of the pipe. Piping shall not be terminated or butt welded within the
bend. If a circumferential butt weld in the arc of a pipe bend is necessary, the bending
process shall comply with PFI Standard ES-24 and require Buyer's prior approval via
the SDDR process. The circumferential butt weld shall be radiographed prior to and
after bending.
5.1.10 Pipe bending methods, tolerances, processes, and material requirements shall comply
with PFI Standard ES-24 and require Buyer's approval. These requirements shall
apply equally to tube bending processes. Seller shall submit a pipe bending procedure
for Buyer review prior to use.
5.2 Layout
5.2.1 Plate size shall be chosen to minimize welding. For horizontal vessels, the
longitudinal seams in cylindrical shells and conical heads shall be located above the
specified normal operating level, where practical. Longitudinal seams shall be
completed before welding any adjoining circumferential seam.
5.2.2 The longitudinal seams of adjacent shell courses shall be staggered by a minimum
length (measured from the toe of the welds) of 5 times the plate thickness, or 4 inches
whichever is greater. Where it is considered impractical to meet this requirement,
Seller shall submit a proposed layout to the Buyer for approval via the SDDR process.
5.2.3 For large diameter formed heads, where two or more plates are butt welded prior to
forming, the butt welds shall be located such that the weld in the knuckle region is
minimized.
5.2.4 Saddles shall be continuously welded to the shell. Welded seams under the saddle or
wear plate are not permitted. Longitudinal weld seams in the shell should not be
located within 15 degrees of the horn of the saddle or wear plate.
5.2.5 Plate layouts shall be arranged so that longitudinal and circumferential weld seams
clear all nozzles, manways, and their reinforcing pads to the maximum extent
possible. A minimum clearance of eight times the plate thickness from the toes of the
welds is required. Where it is considered impractical to meet this requirement, Seller
shall submit a proposed layout of all weld joints to the Buyer for approval via the
SDDR process.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 6, Page 6-12
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
5.2.6 Structural attachment welds such as internal support rings or clips, external stiffening
rings, insulation support rings, and ladder, platform or pipe support clips shall clear
weld seams by a minimum of 2 inches. If overlap of pad type structural attachments
and weld seams is unavoidable, the portion of the seam to be covered shall be ground
flush and radiographically examined before the attachment is welded. The seam shall
be radiographed per ASME Section VIII, Division 1, Paragraph UW-51 for a
minimum distance of 2 inches beyond the edge of the overlapping attachment. Any
protrusion through the weld seam when unavoidable shall be radiographically
examined after completing the joint weld for at least minimum distance of 8 times the
thickness of thicker material at protrusion. Radiographic examination of longitudinal
weld seams is not required when single plate edge type attachments such as tray
support rings, stiffening rings, insulation support rings, ladder, platform, or pipe
support clips cross such weld seams.
5.3 Nozzles, Manways,
and Reinforcing Pads
5.3.1 For forged nozzles connecting to pipe of lesser wall thickness, the Seller shall prepare
the nozzles per ASME Section VIII, Division 1, Figure UW-13.4.
5.3.2 If a manway is specified with a welded cover, the cover shall be tack welded to the
manway neck, prepared for field welding to the manway neck, sealed to prevent dirt
and water from entering the vessel using adhesive tape which meets the contact
material requirements. The cover shall be marked with the plant item number of the
vessel.
5.3.3 Nozzles to be butt welded to connecting pipe shall be prepared for field welding and
fitted with a plastic or rubber protective cover and sealed to prevent dirt and water
from entering the vessel using adhesive tape which meets the contact material
requirements.
5.4 Welding
Requirements
5.4.1 Seller shall comply with 24590-WTP-3PS-MVB2-T0001, Engineering Specification
for Welding of Pressure Vessels, Heat Exchangers and Boilers .
5.4.2 All welding shall be continuous. Stitch welding is prohibited.
5.4.3 Joints shall be assembled and retained in position for welding. The use of
manipulators or other devices to permit welding in the flat position should be
employed where practical.
5.4.4 All attachments such as lugs, brackets, nozzles, pads and reinforcements around
openings and other members (when permitted) shall follow the contour and shape of
the surface to which they will be attached. The gap at all exposed edges to be welded
shall not exceed the greater of 1/16 inch or 1/20 of the thickness of the attachment at
the point of attachment.
5.4.5 Where fillet welds only are used, the maximum gap between the components being
joined shall be 1/8 inch. The components shall be clamped or otherwise maintained
together during welding.
5.4.6 Attachment point of spiders, braces, or other temporary attachments shall match the
material of the vessel.
5.4.7 All temporary attachments shall be removed prior to shop hydrotest unless specifically
approved by the Buyer.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 6, Page 6-13
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
5.4.8 Where practical, internal structural components and piping welds shall be full
penetration. If it is not practical, seller shall propose fillet welded attachments for
Buyer approval via the SDDR process.
6 Design and NDE
Requirements
6.1 All Design Levels
6.1.1 The shell and head sections which are subjected to concentrated or large loads through
welded attachments (such as lifting and tailing lugs) shall, prior to welding, be
ultrasonically examined over 100 percent of the areas, in accordance with the
following:
• For connections or attachments directly welded to the shell or head, the area tested
shall extend 3 inches beyond the extremity of the proposed weldment
• For connections or attachments welded via a reinforcement or doubler plate, the
shell area tested shall extend 5 inches beyond each side of the perimeter of the
proposed fillet weld attaching the reinforcing or doubler plate to the shell or head
• Not required for nozzle penetrations.
6.1.2 All full penetration welds attaching internal or external structural components to the
heads or shell shall be ultrasonically tested. If fillet welds except for Lifting and
Tailing Lugs are permitted by writing by the Buyer and are not readily ultrasonically
tested, they may be dye penetrant tested or magnetic particle tested with approval from
the Buyer via the SDDR process.
6.1.3 All full penetration welds forming part of the jacket shall be ultrasonically tested.
6.1.6 Additional NDE requirements are specified in the drawings and MDS.
6.4 Additional
Requirements for
Commercial Grade
(CM) Vessels
6.4.1 Nozzles may use either a pad or integral reinforcement.
6.4.2 The following weldments shall be subject to volumetric testing unless otherwise
indicated on the MDS or Drawings:
• At least 10 percent of the length of each welder's production of vessel main seams
butt welds. The minimum extent of volumetric testing shall include all "T" junctions
and 10 percent of the remaining longitudinal weld with a 6 inch minimum length of
volumetric testing.
• For nozzle-to-shell welds located in the Primary Containment, at least 10 percent of
the number of welds made by each welder over 100 percent of its circumference.
• At least 10 percent of butt welds in internal piping for the full circumference.
Radiography is the preferred method of volumetric testing. Where it is considered
impractical to perform radiographic examination due to joint configuration, the Seller
may propose ultrasonic examinations; the seller shall use the SDDR process to
propose ultrasonic examinations. The SDDR shall include UT procedure reference,
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 6, Page 6-14
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
technical justification of UT proposal for every weldment and schematic location of
every weldment proposed to be UT tested.
7 Tests and
Inspections
7.1 Hardness Testing
for Austenitic Stainless
Steel Components
7.1.1 Hardness testing is required when austenitic stainless steel plates are cold formed to
make sections such as angles, channels, and conical sections. This requirement is not
applicable to the cold forming of dished heads, which is covered by the relevant
section of ASME Section VIII, Division 1.
7.1.2 Hardness testing is required when austenitic stainless steel pipe is cold formed for
bends with a centerline radius less than three times the nominal pipe diameter.
7.1.3 Any cold forming process, which may significantly increase hardness, shall be in
accordance with an approved procedure, which contains hardness testing. The
procedure shall be submitted for Buyer's approval.
7.1.4 Hardness testing shall be performed on areas subject to the greatest deformation after
cold working or any rework or rectification. The maximum permitted hardness is HRB
92 or as indicated by the material specification acceptance criteria for hardness.
7.1.5 If the maximum permitted hardness is exceeded, the Seller shall solution anneal (heat
treatment) in accordance with the applicable ASME specification for that material.
Heat Treatment process shall include heating and cooling rates, thermocouple
locations, and type of heating equipment. Seller shall submit a written procedure for
suitable heat treatment and testing for Buyer's approval.
7.2 Nondestructive
Examinations
7.2.1 Radiography, ultrasonic testing, visual examination, magnetic particle, and dye
penetrant examination, where specified or required, shall be performed in accordance
with ASME Section VIII, Division 1 and ASME Section V, and procedures developed
and submitted to the Buyer for review prior to use.
7.2.2 All mandatory nondestructive examination (visual, surface flaw, and volumetric) shall
be carried out after the completion of fabrication, including any heat treatment. Where
Seller carries out additional nondestructive examination prior to any heat treatment
process, such examinations shall be included in the Quality Plan or Inspection
Schedule. The Buyer's representative need not witness this additional nondestructive
examination; however, the records of such inspection shall be made available to the
Buyer's representative.
7.2.3 Nondestructive examination must be performed by an inspector certified to the
requirements of SNT-TC-1A. The interpretation of the results shall be by either Level
II or Level III inspectors certified to SNT-TC-1A. Visual examination is not included
in this requirement.
7.2.3.1 All weld visual examinations shall be performed by personnel certified in accordance
with American Society for Non-Destructive testing (ASNT) Recommended practice
SNT-TC-1A, Level I, II, or III or certified in accordance with AWS QC-1 as either a
Certified Welding Inspector (CWI) or a Senior Certified Weld Inspector (SCWI)
7.2.4 Ultrasonic testing, where specified by the Buyer or proposed by the Seller, shall be in
accordance with Appendix 12 of ASME Section VIII, Division 1.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 6, Page 6-15
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
7.2.5 Radiographic acceptance criteria shall be in accordance with ASME Section VIII,
Division 1, Paragraph UW-51 where full radiography is required or UW-52 where
spot radiography as defined in this exhibit is per Section 6.4.2.
7.2.7 Dye Penetrant testing, where specified by the Buyer or proposed by the Seller, shall be
in accordance with Appendix 8 of ASME Section VIII, Division 1.
7.2.8 Magnetic Particle testing, where specified by the Buyer or proposed by the Seller,
shall be in accordance with Appendix 6 of ASME Section VIII, Division 1.
7.2.9 Weld visual examination, where specified by the Buyer or proposed by the Seller,
shall be in accordance with ASME Section V, Article 9.
7.2.10 Fillet Weld Measurement:
• A fillet weld leg size specified on the drawing weld symbol is the minimum size
required 360 degrees around the nozzle/attachment. The effective throat based on that
fillet size must be fully met around that circumference, including the obtuse
(downhill) location. Both leg and throat dimensions must be met as an example, for a
specified fillet weld leg size of 1/4", the throat thickness on the obtuse side as shown
in the figure below is NOT acceptable (less than 0.707 x 1/4") and consequently the
actual leg size must be increased on the obtuse side to meet an effective throat
thickness of 0.707 x 1/4". For angles greater than 135 degrees, submit an SDDR for
buyer review and approval. Fillet weld design is applicable between 60 degrees and
135 degrees (per AWS D1.1, Section 16, D1.6 Annex B) any weld outside these limits
is not considered a fillet weld and shall be designed accordingly.
7.3 Hydrotests
I 4 = IZC
Obn1 e ide
et zzl Fillet dd
= 0 .::! 17 for 60")
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 6, Page 6-16
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
7.3.1 If paint is specified, the vessel shall not be painted prior to the pressure test. Coating
shall not be applied to external welds of items requiring leak/hydrostatic testing prior
to testing.
7.3.2 All welds shall be sufficiently cleaned and free of scale or paint prior to hydrostatic
testing.
7.3.3 Testing of vessels or components made of austenitic stainless steel materials shall be
conducted with potable water containing no more than 50 PPM chloride.
7.3.4 For vessels of low alloy steel, before application of the test pressure, the test water and
the vessel material shall be allowed to equalize to approximately the same
temperature. The temperature of the pressure resisting components during the pressure
test, regardless of test media, shall be at least 30 °F warmer than the minimum design
metal temperature to be stamped on the nameplate, but need not exceed 120 °F.
7.3.6 After completion of the hydrostatic test, the vessel shall be drained, dried, cleaned
thoroughly inside and outside to remove grease, loose scale, rust, and dirt and closed
as quickly as practicable. Test water shall not be in contact with austenitic stainless
steel for more than 72 hours, unless treated with an appropriate biocide.
7.3.7 If field assembly or erection is involved, the final hydrostatic test shall be at the job
site. The Seller or the field subcontractor shall provide the Buyer with a detailed test
procedure for review and approval prior to testing.
7.3.8 A horizontal vessel shall be tested while resting on its support saddles without
additional supports or cribbing.
7.3.9 Tall vertical vessels may be shop hydrotested in the horizontal position. The vessel
shall be designed for vertical hydrotest loading. These vessel supports must be
adequately designed to support the vessel (in accordance with the ASME code) during
the hydrotest to prevent damage.
7.3.10 Each chamber of a multi-chamber vessel (jacketed vessel) shall be subject to a
hydrotest pressure with atmospheric pressure in the adjacent chamber.
7.3.12 Seller shall submit a hydrostatic test procedure in accordance with the requirements of
Section 7.3 of this exhibit and ASME Section VIII, Division 1, Paragraph UG-99 for
buyer review prior to use.
7.4 Leak Tests
7.4.1 If gas or pneumatic testing is specified in the MDS, Drawings or in the purchase order,
the Seller shall conduct the tests in accordance with ASME Section V. Seller shall
submit a test procedure for Buyer review prior to use.
7.4.2 Reinforcing pad attachment welds and accessible surfaces of inside nozzle to vessel
wall welds shall be tested for leaks with 15 PSIG dry air or nitrogen and bubble
forming solution. This test shall be performed prior to the final hydrostatic or
pneumatic test as applicable.
7.5 Obstruction Test
7.5.1 Seller shall ensure and document that all internals, internal piping, and jacketing are
free from obstructions.
7.6 Final Inspection of
Completed Vessel
7.6.1 Final inspection of the completed vessel shall be the sole responsibility of the Seller.
The finished dimensions and cleanliness of the vessels shall comply with the relevant
Drawings and specifications after completion of all tests.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 6, Page 6-17
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
8 Preparation and
Shipment
8.1 Cleaning
8.1.1 Seller shall comply with 24590-WTP-3PS-G000-T0003.
8.1.2 If specified in the purchase order and in any event following hot working or heat
treatment, the equipment shall be descaled. The procedure to be used by Seller shall be
submitted for Buyer's prior approval.
8.1.3 If blast (mechanical) descaling process is specified in the purchase order for stainless
steel construction, clean and iron-free glass or ceramic beads, or sand of alumina or
zirconia type shall be used. The type, grade, and chemical composition of the abrasive
shall be submitted for Buyer's approval prior to its use. Recycling of abrasive is
prohibited. Blast cleaning shall not be used on weld metal or as a final finish on
fabrications.
8.2 Packaging
8.2.2 All flanged openings, which are not provided with a cover, shall be protected by an
ASME B16.5 or B16.47 carbon steel blind flange of the same rating as the flange, a
full faced rubber gasket with a minimum thickness of 1/8 inch and carbon steel bolts
with stainless steel washers.
8.2.3 For internal parts, suitable supports shall be provided to avoid damage during
shipment. Temporary internal bracing shall be painted yellow and a label, located near
the nameplate shall state that the vessel contains temporary bracing that must be
removed.
8.2.4 Small parts, which are to be shipped loose, shall be bagged or boxed and marked with
the order and plant item number of the vessel.
8.3 Shipping
8.3.1 Seller shall take all necessary precautions in loading by blocking and bracing the
vessel and furnishing all necessary material to prevent damage.
8.3.2 The Seller shall verify, by calculation, that the vessel and internals will withstand
loads occurring during shipping for the chosen mode of transportation. The Buyer
shall inform the Seller of the chosen mode of transportation
9 Documentation and
Submittals
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 6, Page 6-18
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
9.2 Design calculations shall include relevant ASME Section VIII, Division 1 formulas,
and source paragraphs, values used in the formulas, the calculated results, and
comparison with acceptable values. Where calculations are based on other than the
ASME Section VIII, Division 1 formulas, the source of the formulas shall be
referenced. Where a computer program is used for calculations, a brief program
description shall be given, including name and version of the program. If the program
is not commercially available to industry, Seller shall maintain and provide, upon
request, program documentation. Calculations shall include, but not be limited to:
• Code calculations
• Nozzle neck calculation per UG45, average primary stress Pm across the nozzle
wall
• Seismic calculations including base horizontal seismic force and moment and loads
for anchorage and anchor bolt design
• Support calculations including empty weight, operating weight and location of
center of gravity
• Calculations associated with lifting and erection of the vessel
• Nozzle load analysis for local and gross effect, per Section 3.7 above, or by other
approved method
• Design of attachments, both internal and external
• Thermal and discontinuity stresses as applicable
• Fatigue analysis as applicable for vessels in fatigue services
9.2.1 Seller shall submit an Outline drawing for each item. The Outline drawing shall
include the following minimum for each item:
• Shell and head thickness
• Head type
• Vessel empty weight, test weight and shipping weight
• Center of Gravity
• Lifting lugs and tailing lugs
• Diameter, tangent-to-tangent dimensions and appropriate support details
• Nozzle, flange support locations from datum point
• Nozzle schedule with nozzle marks and service conditions
• All appropriate design conditions, NDE and materials of construction
• Foundation/Mounting details
• Installations of appropriate internals
9.3 Seller shall make a complete set of Buyer approved drawings and other documents
available to the Buyer's representative at the time the quality surveillance activities are
being conducted.
9.4 All records pertaining to the nondestructive examination, base materials, filler
materials, fabrication, and inspection shall be traceable to the area and part inspected
and is accessible for Buyer's examination.
9.5 Seller shall provide ASME Section VIII, Division 1 data reports per ASME Section
VIII Division 1, Paragraph UG-120.
9.6 Seller shall submit assembly drawings and shop detail drawings for buyer's review.
These drawings shall include bill of materials, weld symbol, and NDE for each weld,
and parts used in vessel construction. Assembly and shop detail drawings shall also
include shell and head plate layout (including nozzles) for compliance with Section
5.2 of this exhibit.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 6, Page 6-19
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
9.7 Seller shall provide a detailed description of their work inspections and tests planned
during the receipt of materials, manufacturing, testing, and conformance verification
activities. This shall include identification of Bechtel and supplier witness and hold
points.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 6, Page A-1
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Appendix A
Minimum Nozzle Design Loads
Horizon tal Shell Top Nozzle Horizon tal Shell. Bottom Nonie
~ I---------,.,
r.
:J_,_"'"', '---',' ... v
Vertical Shell Horizonta l Nozzle Horiwnlal Head Noule
M ,
~o 0 M~9 ~. F .
M ,
F, p ~- a ( )
(
Ver tical Bottom Hc,1cl Nozzle Vertical Top Head Nozzle
~
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 6, Page A-2
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Table A2- Minimum Nozzle Loads Due to Stain less Steel Piping on Vessels Dcsi1mated as SC-I I. I l l. and IV
Pi1-.e Size Load T~·re Furc:ts Momen1s Fx (lbl IFv Obi IFz Obi Mx (ft•lbl IMv (ft-lb) IMz (ft•lbl
\\'cigh1 10 1(1 10 I I 7 7 I in S, . .-i:-..mic (16 44 66 92 137 137
Th~rmal 28 24 38 38 77 77 Wciid1t 20 32 20 26 16 16
1-l/2in s~ismic 138 92 138 228 3-12 342 1 h~l'mal 58 52 7R 96 192 192 Weigh! 3-1 56 34 4() 29 29
2 in Seismic H 4 162 244 398 597 597 rhc1·nu1 I 1!14 92 1.18 1<>9 337 337 Weight 71 11 3 71 180 112 11 2
3 in Seismic 491 327 491 1570 2350 2350 I hcrm:il 209 185 278 (,(,.I 1330 1330 \ \'cighl 120 1'12 120 3.J2 214 214
4 in St'ismic 834 557 834 291,0 4440 4440 Thermal 356 317 474 1260 2520 2520 Weight 290 462 290 951 595 595
6 in Seismic 2025 1350 2025 8290 12-100 12400 l l tcrmal 875 777 11 70 3580 7160 7160 Weig.ht 333 5~4 ~l , ,.) 1210 758 758
8 in Seismic 231,0 1580 23<>0 10700 16000 16000 Thermal 1050 938 1410 4800 9590 9590 Weight 361 578 361 22IO 1380 1380
10 in 18-.:ismi'-' 2540 16?0 2540 1?400 ~•>100 2') 100 rhcrmal 11 10 991 1490 8500 17()()0 170{)0 \\'eight 502 803 502 3240 2020 2020
12 in Seismic 3510 2340 3510 28100 ~2100 42 100 I h\!rn1:.1I 1550 1:\80 207() 12400 24800 24800 Weight 59 ) 946 591 3870 2420 2420
14 in ~l'ismic 4 )(,0 2780 4 )(,I) 3390() 50900 50900 rl1crmal )850 16~0 2460 15000 30100 30)00 Wci£ht 757 1210 757 5080 3180 3 )80
16 in Sei:-mil'. 53 10 3540 5:110 44100 (,6100 66 100 ·n1c.·rmal 238() 2 )20 3 )8() 19800 39500 39500 Weigh! 1100 1930 1200 8190 5120 5120
IR in Seismic R~90 5660 8~90 71500 107000 107000 '11lt·nnal 2990 26(,0 3980 25200 50300 50300 Wcigh1 1280 2050 )280 8630 5400 5~(\()
20in Seismic 8910 5<1~0 8910 75900 114000 114000 Thcrmnl 3660 32(,0 4880 312/JO 62400 62400 Weight 1380 2200 1380 '1380 5860 5860
22 in Seismic 95 )0 6340 9510 81500 )22000 122000 ·n1cr111al ~~20 39~0 5900 37900 75800 75800 Weight 1600 2570 1600 I IOOO 6870 6870
24 in Seismic 11100 7430 )1100 96 100 )4400() 144000 l'llermal 52-10 4660 6990 ~5200 90400 90400
Note: Unless othern·isc specified on the MOS utilize the minimum nozzle loads specified
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 6, Page A-3
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Table A4- Minimum Nozzle Loads Due 10 Carbon S1ccl Piping.on Vesse ls Desi0 nated as SC-I I 111 or IV ·-
Pipe Size l ,oatl T ~ pc Forn·, Moment, Fx (lb) IFv (lb) IFz (lb) Mx (ft-lb) IMv (ft-lb) IMz (ft-lb)
ll'cighl 10 16 10 1J 8 8 I in Sci:,;mic (,8 46 68 110 IM 166
I hcnnal 32 30 44 53 106 106 \V~ighl w 32 20 31 2(1 20
1-1 /2 in Sei~mic 140 91 140 275 41 2 412 'll1cr111al <,8 60 90 132 21>5 265 Weigh! J~ 54 34 55 34 3-l
2 in Seismic 234 156 23-1 480 71 1 72 1 rh.:nnal 114 100 150 232 465 465 ll'cighl 1,2 99 <,2 176 110 110
3 in Seismic 482 32 1 482 1910 2870 2&70 Thermal 231 206 308 ') 15 1830 1830 ll'eighl 104 167 104 335 209 209
-tin Seismic 804 53(, 804 3610 5420 5H0 l'hcnnal 387 344 516 1740 3480 3480 \\'d gh1 243 389 243 9-19 593 S93
{, in Seismic 18(,0 1250 1860 10200 15200 15200 lherm:,1 906 80/.> 1210 4930 9870 9870 Weigh! 353 564 353 1450 903 903
8 in Seismic 2690 1800 2690 13400 20200 20200 Thermal 1320 II 80 1770 6610 13200 13200 W.:ighl 384 61 5 384 2600 1(,30 1630
Hl in Seb.rnic 2920 1950 2920 23700 35(,00 35600 Thermal 1450 1290 1930 11 700 2340() 23400 W.:igh1 567 908 567 4150 2590 2590
12 in Sei~mk 43 IO 28SO 43 IO 37100 551i00 55600 Th~rmal 2140 1910 2860 18400 3(,800 36800 Weight 707 11 30 707 54()() 3380 3380
14 in S1..d:-mk 5380 3590 5380 ~8100 72200 72200 Thermal 2(,70 2380 3570 23900 -17900 47900 Weight 980 1570 980 S().10 5020 5020
16 i,1 S11h,mic 7~5() ~970 7450 71900 108000 IOROOO 1111:rrnal 3700 3290 ~940 35800 71500 71500 \ \fciglH 1300 2080 IJ()(I 11300 7090 709()
18 in S,·ismic 9890 6590 9890 102000 152000 152000 1 hcrnrnl 4950 4~00 6600 50900 102000 102000 Wcigh1 16~0 2(,30 1640 149()0 9330 9)30
20 in Seismic 12500 8320 12500 132000 198000 198000 Thc-nn,11 6300 5(,00 8400 66500 133000 IJ.1000 \Vcigh1 1900 3040 1900 15400 9620 9620
22 in Seismic 14400 % 10 14400 1350(10 203000 20300() ·n 1lTl11al 7330 6520 9770 68800 138000 138000 Weig.hi 2510 4020 25)0 24~00 15500 ISSOO
2-1 in Scbanic 19000 12700 19000 217000 326000 326000 Thermal 9760 8680 13000 l liOOO 222000 222000
Note: Unless otherwise specified on the MDS utilize- the minimum nozzle loads s pecified
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility
Atmospheric Process Vessels
Exhibit 7, Page 7-1 24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
EXHIBIT 7 | SEISMIC QUALIFICATION CRITERIA FOR PRESSURE VESSELS
Specification 24590-WTP-3PS-MV00-T0002, REVISION 3 was used as applicable to create
the following exhibit. Specification change notices (SCNs) have been evaluated and there
are no applicable SCNs.
Note: All References on this exhibit are inclusive to this exhibit only.
Specification Requirement
1. Scope
1.1 This exhibit covers pressure vessel seismic analysis criteria and supplements the
requirements of the exhibits listed in Section 2.3.
1.2 This document shall be used by the vessel equipment designer.
2 Applicable
Documents
2.2 Codes and
Industry Standards
2.2.1 American Society of Mechanical Engineers, Boiler and Pressure Vessel Code
2.2.1.1 ASME Section VIII, Division l, "Rules for Construction of Pressure Vessels"
2.2.1.2 ASME Section VIII, Division 2, Rules for Construction of Pressure Vessels -
Alternative
Rules, American Society of Mechanical Engineers (Note: Code year not later than 2004
Edition with 2005 and 2006 Addenda). Linearization of Stress Results for Stress
Analysis (ASME VIII Div 2, Annex 5.A, 2007 Edition, no Addenda)
2.2.1.3 ASME Section Il, Part D, "Properties"
2.2.2 UBC, 1997 Uniform Building Code
2.2.3 AISC MO 16, ASD Manual, of Steel Construction, "9th Edition, American Institute of
Steel Construction
2.2.4 DOE-STD-1020-94, Department of Energy, "Natural Phenomena Hazards Design and
Evaluation for the Department of Energy Facilities", including change notice dated
January 1996
2.2.5 ASME B31.3, Process Piping, 1996, American Society of Mechanical Engineers
2.3 Project
Documents
2.3.2 Exhibit 2 of 24590-BOF-3PS-MVSC-T0002 , Structural Design Loads for Seismic
Category IV Equipment and Tanks
2.3.3 Exhibit 6 of 24590-BOF-3PS-MVSC-T0002, Pressure vessel Design and Fabrication
3 Abbreviations
and Definitions
EQD Equipment Qualification Data Sheet
MDS Mechanical Data Sheet
NPH Natural Phenomena Hazard
Performance
Category
Per DOE-STD-1020-94, each SSC is assigned a
NPH Performance Category ranging from PC-0
through PC-4
RPP-WTP River Protection Project - Waste Treatment Plant
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility
Atmospheric Process Vessels
Exhibit 7, Page 7-2 24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
SC Seismic Category
SC-I, II, III, IV Specifies the required seismic category of an
equipment item. Refer to Exhibit 3 for a more
detailed explanation.
Seismic Loading Seismic loading is defined in terms of a site-
specified design response spectrum, also referred to
as Design Basis Earthquake (DBE), or specified for
the site by Uniform Building Code (UBC)
SSC Structures, Systems and Components
5 Buyer's
Responsibilities
5.2 The Buyer provides the Seismic Response Spectra where necessary to perform the
seismic analysis.
6 Seller's
Responsibilities
6.1 The Seller is responsible for the seismic analysis of the vessels according to the
assigned Seismic Category. The Seller shall ensure that stresses in the vessel do not
exceed those allowed, as defined in Section 7.4 for the vessel proper and reference 2.3.3
for the vessel supports, for the required loads and combinations thereof.
6.2 Depending on the Seismic Category of the vessel and its internal components, a finite
element analysis may be required to determine the vessel stresses when subjected to
operating and seismic loading. The software and implementation used for the analysis
shall be in accordance with the quality assurance requirements defined in the purchase
order.
6.3 The Seller shall obtain approval from the Buyer before nominating others to perform the
design services.
7 Design
Requirements
7.1 Seismic
Category
7.1.1 The RPP-WTP Structures, Systems, and Components (SSC) are categorized as SC-I, II,
III, or IV. The SC level is based upon the contents and the required functionality of the
SSC following a seismic event. The Seismic Category defines the applicable analysis
method and the acceptance criteria.
7.1.2 Seismic loading shall not be considered when performing the primary plus secondary
stress range analysis required by Section VIII, Division 2, Appendix 4. In addition,
seismic loading shall not be considered when performing a fatigue analysis required by
Section VIII, Division 2, Appendix 5.
7.1.3 As indicated in UG-23(c), seismic loads are combined with normal operating loads
when applying the factor of 1.2 to the allowable stress. Seismic loading and wind
loading or Multiple Overblow need not be considered to act simultaneously.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility
Atmospheric Process Vessels
Exhibit 7, Page 7-3 24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
7.1.4 NPH Performance Categories for each SSC are assigned using criteria specified in
DOE-STD-1020-94, and range from PC-0 through PC-4 depending on overall risk of
the facility operation and the assigned function to the SSC. The following table
summarizes the descriptions of the NPH Performance Categories as defined in DOE-
STD-1020-94 and the correlation to Seismic Category:
7.2 Design Code
7.2.1 The governing design code for the vessel proper is ASME Section VIII, Division l. The
loadings to be considered in designing the vessel shall include those listed in paragraph
UG-22 of the code.
7.2.2 The governing design code for the vessel supports is as per Exhibit 6 of 24590-BOF-
3PS-MVSC-T0002 Pressure Vessel Design and Fabrication.
7.3 Seismic
Analysis
7.3.1 Internal components, supports, and piping systems shall be analyzed the same as the
parent vessel unless otherwise noted. Requirements for internal piping and supports are
provided in Reference 2.3.3.
7.3.3 The seismic loads for SC-III and SC-IV vessels shall be determined according to
Exhibit 2 of 24590-BOF-3PS-MVSC-T0002. Factors for UBC equations are given in
Section 4.0 of that exhibit.
7.3.5 The seismic analysis of SC-III and SC-IV vessels and their supports shall be performed
in accordance with specification Exhibit 2 of 24590-BOF-3PS-MVSC-T0002 and
Exhibit 6 of 24590-BOF-3PS-MVSC-T0002.
7.4 Maximum
Allowable Stresses
and Acceptance
Criteria for the
Vessel Proper
7.4.1 Maximum Allowable Tensile Stress - The maximum allowable tensile stress, S, for the
material of construction of the vessel shall be as specified in ASME Section II, Part D,
and Subpart 1 .
Performance Performance Goal Description RPP-WTP Seismic Category Category (SC)
PC-0 No safety, mission, or cost considerations SC-V
PC-1 Maintain occupant safety SC-IV
PC-2 Occupant safety, continued operation with minimum SC-III interruption.
PC-3 Occupant safety, continued operation, hazard SC-II or SC-I confinement.
PC--4 Occupant safety, continued operation, confidence of Not required for this hazard confinement. project
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility
Atmospheric Process Vessels
Exhibit 7, Page 7-4 24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
7.4.2 Maximum Allowable Longitudinal Compressive Stress - The maximum allowable
longitudinal compressive stress used in the vessel design shall meet the requirements of
paragraph UG-23(b) of the ASME Section VIII, Division 1.
7.4.3 Maximum General Primary Membrane Stress - The wall thickness of a vessel shall be
determined such that the induced maximum general primary membrane stress does not
exceed the maximum allowable stress in tension for any combination of loadings listed
in paragraph UG-22 of ASME Section VIII, Division 1 that induce primary stresses and
are expected to occur simultaneously during normal operation of the vessel.
7.4.4 Combined Primary Membrane plus Primary Bending Stress - The combination of loads
as discussed in Section 7.4.3 shall not induce a combined maximum primary membrane
stress plus primary bending stress across the vessel wall thickness, that exceeds 1.5
times the maximum allowable stress value in tension.
7.4.5 Combination of Seismic Loadings with Other Loadings - For the combination of
seismic loading with other loadings in UG-22, the wall thickness of a vessel shall be
determined such that the general primary membrane stress shall not exceed 1.2 times
the permitted maximum allowable stress, as defined in 7.4.1, 7.4.2, 7.4.3 or 7.4.4.
Seismic loading and wind loading or Multiple Overblow need not be considered to act
simultaneously. As indicated in UG-23(c), seismic loads are combined with normal
operating loads when applying the factor of 1.2 to the allowable stress.
Note that ASME Section VIII, Division l, UG-23(d) is silent relative to any stresses
other than General Primary Membrane, i.e., it does not address the same types of
stresses (Local Primary Membrane, Primary Membrane plus Primary Bending) in the
detail addressed in Section VIII, Division 2. Local Primary Membrane stress is
discussed in ASME Section VIII, Division 2, Paragraph AD-140(c) and is limited to
1.5kSm, as is Primary Bending stress (AD-140(d)). Table AD-150.1 of ASME Section
VIII, Division 2, then provides guidance for "k" under Design and other conditions. In
accordance with that Table and in accordance with the commitment to use S vs. Sm, a
factor of 1.2 times the permitted allowable stress in 7.44 above shall be used for Local
Primary Membrane or Primary Bending evaluations that include seismic loading (i.e.,
1.2 x 1.5 x S).
7.4.8 The acceptance criteria for non-safety vessels shall be in accordance with ASME
Section VIII, Division 1, using the allowable stress, S, from ASME Section VIII,
Division 1.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 8, Page 8-1
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
EXHIBIT 8
Deleted.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 9, Page 9-1 24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
EXHIBIT 9
Deleted.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 10, Page 10-1
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
EXHIBIT 10 | TECHNICAL SUPPLY CONDITIONS FOR PIPE, FITTINGS, AND FLANGES
Specification 24590-WTP-3PS-PB01-T0001, REVISION 9 was used as applicable to create the
following exhibit. Specification change notices (SCNs) have been evaluated and there are no
applicable SCNs.
Note: All References on this exhibit are inclusive to this exhibit only.
Specification Requirement
1 Scope
1.1 This document specifies the minimum requirements governing the supply of metallic pipe,
fittings, and flanges for piping in accordance with ASME B31.3 - 1996, Process Piping.
This document is not applicable for temporary or non-permanent plant installation. The
term pipe and related requirements listed in this exhibit are applicable to stainless steel tube.
1.2 This exhibit shall be applicable to all material requisitions or purchase order packages for
pipe, fittings, and flanges purchased in accordance with the requirements of the referenced
Codes and Standards specified below, unless technical and quality requirements are
specified on other approved engineering documents.
2 Code, Standards
& References
2.1 ASME B31.3 - 1996, Process Piping, is the piping code for the WTP Project.
ASME materials, identified in ASME Boiler & Pressure Vessel Code, Section II Material
Specifications, as being identical to the ASTM Material Specifications, for the edition year
listed below, alloy, type and / or grade, (if applicable), are acceptable for use.
When using ASTM material specifications for commercial material (CM) items, any
version more recent than the ASTM version referenced in ASME B31.3 - 1996 Appendix
E, is acceptable. A SDDR is not required for these CM item ASTM material specification
edition changes.
ASME Standards
ASME 831.3, - 1996 Acceptable Later edition, Appendix E listed Standard Edition Standard and Edition Date Dated Through
ASME816.5 1988 2009 Pipe Flanges and Flanged Fittings NPS i /2 Through NPS 24 Metric/Inches
ASME816.9 1986 2007 Factory-Made Wrought 8uttwelding Fittings**
ASME816.11 1991 2009 Forged Fittings, Socket-Welding and Threaded
ASME 816.25 1986 --- 8uttwelding Ends
ASMEBl6.28 1986 --- Wrought Steel Buttwelding Short Radius Elbows and Returns
ASMEB16.36 1988 2009 Orifice Flanges
ASMEB16.47 1990 -- Large Diameter Steel Flanges NPS 26 through NPS 60
ASME B36. l0M 1985 --- Welded and Seamless Wrought Steel Pipe
ASME 836.19M 1985 --- Stainless Steel Pipe
ASME B 1.20.1 1983 --- Pipe Threads, General Purpose (Inch)
** SR ells are now supplied in accordance with ASME B16.9 and are acceptable. ASME B16.28 is replaced by ASME B1 6.9.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 10, Page 10-2
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
American Society for Testing and Materials (ASTM) Material Specifications
ASME B3 l.3, - 1996 Acceptable Alternate edition, Appendix E bstcd V crsions Dated Standard and Edition Date Through
ASTMA36 1993a 2008 Standard Specification for Carbon Structural Steel
ASTMA53 1993a 2010 Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless
ASTM Al05 1993b 2010a Standard Specification for Carbon Steel Forgings for Piping Applications
ASTMAI06 1993 2010 Standard Specification for Seamless Carbon Steel Pipe for High-Temperature Service
ASTM Al82 1993b 2010a Standard Specification for Forged or Rolled Alloy and Stainless Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature Services
ASTM A234 1992a 2011 Standard Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and High Temperature Service
ASTMA240 1993b 2011 Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications
ASTMA269 1992 2010 Standard Specification for Seamless and Welded Austenitic Stainless Steel Tubing for General Service
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 10, Page 10-3
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
American Society for Testing and Materials (ASTM) Material Specifications
ASME B3 l.3, - 1996 Acceptable Alternate edition, Appendix E listed Versions Dated Standard and Edition Date Through
ASTMA276 1992 2010 Standard Specification for Stainless Steel Bars and Shapes
ASTMA312 1993 2011 Standard Specification for Seamless, Welded, and Heavily Cold Worked Austenitic Stainless Steel Pipes
ASTMA333 1991a 2011 Standard Specification for Standard Specification for Seamless and Welded Steel Pipe for Low-Temperature Service
ASTMA335 1992b --- Standard Specification for Seamless F erritic Alloy-Steel Pipe for High-Temperature Service
ASTMA350 1993 2010 Standard Specification for Carbon and Low-Alloy Steel Forgings, Requiring Notch Toughness Testing for Piping Components
ASTMA351 1991b 2010 Standard Specification for Castings, Austenitic, Austenitic-Ferritic (Duplex), for Pressure-Containing Parts
ASTM A352 1989 --- Standard Specification for Steel Castings, Ferritic and Martensitic, for Pressure-Containing Parts, Suitable for Low-Temperature Service
ASTMA370 1992 2009a Standard Test Methods and Definitions for Mechanical Testing of Steel Products
ASTMA403 1993 2010 Standard Specification for Wrought Austenitic Stainless Steel Piping Fittings
ASTM A420 1992 2010a Standard Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Low-Temperature Service
ASTM B62 1993 --- Standard Specification for Composition Bronze or Ounce Metal Castings
ASTMB337 l 983(RI 987) --- Standard Specification for Seamless and Welded Titanium and Titanium Alloy Pipe
ASTMB363 1983 (Rl987) --- Standard Specification for Seamless and Welded Unalloyed Titanium and Titanium Alloy Welding Fittings
ASTMB366 1991 2010 Standard Specification for Factory-Made Wrought Nickel and Nickel Alloy Fittings
ASTMB381 1993 2010 Standard Specification for Titanium and Titanium Alloy Forgings
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 10, Page 10-4
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
Amerlc-.a.n Society for Testing a11d Materials ( ate:ri:11 Spec:ifkancms
AS!', l331.3, • 199-6 Acceptable Altcm.atc ooilion, Appendix listed Versions Dated Sttmdard and Edi1io11 Date Through
ASTMB444 1990 2006
ASTMB462 1993 2010
AS™ B5114 1993 20!0
AS l B575 1m 20!0
ASTMB.584 1993b
ASTMB619 1992 2010
ASTMB67S 1990a 2002, R-2007
ASTMB68B 1993 1996 (R 009)
ASThIS861 No! Lisred 20 10
ASTMEIO ot Listed 2010
ASTME18 Not Listed 20081.l
ASTM.E.797 NotLisl:c<l 2005
MaDufacturer Stamlardlzatlon Soci.ety (MSS)
MSS SP-25 l9n (R.1988)
Standard Specification for NickdChroruium--Molybdeuun.-C.Olumbium Alloys (UNS N0662S) Pipe and Tub~
Stauclard Spec1ficatio11 for Forged or Rolled UNS NO®OOO UNS N0.8024 UNS N08026, UNS N0.8367, and UNS R20033 Alloy J>ipe Ft.ms es, Forged Fittings, and Valve~ and Parts for CorrMive Hi;gh-f cmpenirure Service.
Sliln"dmd Specification for Nickel Alloy o.gings
Starrulatd Speciftcatiom for Low-Carbon Niclcel-Cbromium-Molyb<knum, LowCarbon Nickd-Ch,omium-Molybdenum• Copp~r. Low-Carbon Nid::el-ChrumiumMolybdcnum- anlal= , and Low-Cmhcm Nickel-Cbromil-lm"Molyb,;lenum-Tu•gijtea,
Alloy Plate, Sheet, aml ltrip,
Sumdard Specification for o~r Al oy Saoo Castings for General Applications
S1:mdard Spccificalioo for Welded Nickel and Nickel-Cobalt
Alloy Pipe
Standltrd Spiwificatio11 for UNS N0&366 1md "083'67 Wddetl Pipe
S dard Spedficario• for ChromiumNickol•Molyb,;lcnum-lroo S 08366 a11d S 08 67) Plal.ll, Sheet, and Strip
Sland.rrd Specilic11;tioo for rnwum and ·n1aruum Alloy Sc-,amlc,~ Pipe
S1amlnrd Te:sl Melltod for Brin11el H.ardtless of Metallic Material~
S~da.rd c,;;I ·Methods fur Rocl:wdl Hafrulc/;.$ a fMetallic Materials
Stlndard Practiee for Measuri:1.1g Tiiiclcness by Manual U1wsonic Pulse-Echo Contaci
etnQd
Stmdard Matkil\g System for Valves, ittings., Flange and Unio
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 10, Page 10-5
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
2.2 General
Specifications
Exhibit 5 of 24590-BOF-3PS-MVSC-T0002 Shop Fabrication of Piping
Exhibit 1 of 24590-BOF-3PS-MVSC-T0002 Positive Material Identification (PMI) for
Shop Fabrication
24590-WTP-3PS-G000-T0003 Packaging, Handling, and Storage Requirements
5 Material
5.2 Except as otherwise specified in purchasing documents, all materials shall be new and shall
be traceable to their Material Test Report (MTR).
5.3 All threaded pipe, fittings, and flanges shall be supplied with threads in accordance with
ASME B1.20.1. Threaded galvanized pipe, fittings, and flanges shall be supplied with
threads free of galvanizing. Couplings ordered with threaded pipe shall be screwed on
"handling-tight" as described in Paragraph 7.2 of API 5L.
5.4 Seamless pipe and fittings, if available, are preferred in all cases.
Welded pipe and fittings are an acceptable substitute for seamless pipe and fittings only per
Buyer approved SDDR unless already noted below.
As required by the ASTM material standard the NDE results shall be shown on the
applicable material test report that is supplied with the material. For RT the acceptance
criteria shall be per UW-51 of ASME Boiler & Pressure vessel Code Section VIII, Division
1. For UT the acceptance criteria for single longitudinal seam welds shall be per UW-53 of
ASME Boiler & Pressure Vessel Code Section VIII, Division l. There are no procedure
submittal requirements for NDE performed by material manufacturers of pipe and fittings
manufactured in accordance with a standard listed in ASME B31.3 Table A-1 or Table
326.1
Where these longitudinal seam weld examinations have not been performed as required by
the material manufacturer, the Supplier shall perform the examinations in accordance with
the above paragraphs, including the following;
The Supplier RT and/or UT procedures used for the above examinations shall be
submitted for Buyer's review and permission to proceed.
The results of these Supplier performed examinations shall be included in the
material documentation package.
5.5 Orifice flanges shall be supplied in pairs complete with jackscrews and plugs, but without
bolts, gaskets, or orifice plates.
Manufacturers Standardization Society (MSS)
MSS-SP-79 1992 2009 Socket Welding Reducer Inserts
MSS SP-83 1987 2006 Class 3000 Steel Pipe Unions Socket Welding and Threaded
MSS SP-95 1986 (R1991) 2006 Swage(d) Nipples and Bull Plugs
MSS SP-97 1987 2006 Integrally Reinforced Forged Branch Outlet F ittings - Socket Welding, Threaded and Buttwclding Ends
American Petroleum Institute
API5L Nov. I , 1992 ----- Specification for Line Pipe Fortieth Edition
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 10, Page 10-6
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
5.6 To ensure material is correctly supplied as specified, the Seller shall perform Positive
Material Identification (PMI) tests in accordance with Specification Exhibit 1 of 24590-
BOF-3PS-MVSC-T0002. The Seller shall submit their PMI test procedure for Buyer's
review and permission to proceed. Note that PMI is not applicable for carbon steel, and
titanium materials.
5.8 The following are approved alternate materials per this exhibit:
5.8.1 Where material is specified as triple stamped, seamless A106/A53/API 5L Grade B, the
following single stamped materials are acceptable:
a) A106 Grade B
b) Seamless A53 Grade B
c) Seamless API 5L Grade B
5.8.2 Where material is specified as double stamped, seamwelded A53/API 5L Grade B, the
following single and triple stamped materials are acceptable:
a) Seamwelded A53 Grade B
b) Seamwelded API 5L Grade B
c) Seamless A53/A106/API 5LGrade B
5.8.3 Where material is specified as dual grade Type 316/316L stainless steel, a single grade
Type 316L is acceptable.
5.8.4 Where material is specified as dual grade Type 304/304L stainless steel, a single grade
Type 304L is acceptable.
5.8.5 Where Buyer's purchase order description specifies pipe to be furnished "Bevelled Both
Ends", pipe furnished with "Plain Ends" is acceptable.
5.8.6 Where Buyer's purchase order description specifies pipe to be furnished "Double Random
Lengths", pipe furnished in "Single Random Lengths" is acceptable unless otherwise noted.
5.8.7 Where ASTM B675, N08367 Class 1 pipe with hydrostatic test is specified, ASTM B675,
N08367 Class 2 pipe with hydrostatic test is acceptable.
5.8.8 Where ASTM A536 Ductile Iron is specified for groove end fittings, Malleable Iron or
Carbon steel are also acceptable consistent with the manufacturer's standard offerings.
5.8.9 External rust staining of austenitic stainless steel and nickel alloys due to contact with
carbon steel is acceptable. This applies to bulk piping materials and not to shop fabricated
spools.
5.8.10 Where ASTM B619 UNS N06022 Class I pipe is specified, ASTM B619 UNS N06022
Class II is acceptable.
5.8.11 Double Submerged-Arc Welded (DSAW) API 5L Grade B is acceptable in lieu of Electric
Resistance Welded (ERW) API 5L Grade B for all pipe sizes larger than NPS 24.
5.8.12 For stainless steel floor drains only, ASTM A351 Grade CF8M is an acceptable substitute
for ASTM A351 Grade CF3M.
5.8.13 Where ASTM A53 Grade B is specified, ASTM A106 Grade B is an acceptable alternate
for NPS 2 and smaller.
5.8.14 Galvanizing of ASTM A106 Grade B shall be per ASTM A153 and/or ASTM A123.
5.8.15 Where malleable iron per ASTM A197 is specified for threaded pipe plugs, ASTM A126
solid cast iron plugs are an acceptable alternate.
5.8.16 Taper boring of standard schedule 40S butt weld reducing fittings, per ASME B16.25, is
permitted where NPS 4 and smaller schedule 40S piping transitions to NPS 6 and larger
schedule 10S piping. The applicable fitting MTRs shall be annotated accordingly.
5.8.18 ASTM B584, UNS C84400 and C83600, is an acceptable alternate material where ASTM
B62 is specified in the stock code description for flanges or fittings.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 10, Page 10-7
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
5.8.19 Where ASTM B366 grades WP6XN, WP6XN-W, or WP6XN-WX are specified in the
stock code descriptions for swages manufactured to the requirements of MSS SP-95,
ASTM B366 grade CR6XN seamless shall be used.
5.8.20 Where ASTM B366 grades WPHC22-S, WPHC22-W, or WPHC22-WX are specified in
the stock code descriptions for swages manufactured to the requirements of MSS SP-95,
ASTM B366 material grade CRHC22 seamless shall be used.
5.8.22 4" pipe size and smaller fittings, and swages marked as ASTM A403 and/or A182 with the
same Grade/Type markings are acceptable for use on Piping Isometrics. No Piping
Isometric bill of material change is required.
5.8.23 MSS SP-25, Standard Marking System for Valves, Fittings, Flanges and Unions, provides
the material marking requirements for pipe, fittings, flanges, and unions.
5.8.24 Please note that certain ASTM standards (e.g., A312) list specific available lengths and do
not use the terms "Double Random Lengths" or "Single Random Lengths". The lengths
specified in the ASTM standard are to be used in those cases.
5.8.25 Stainless steel tubing shall be solution annealed seamless tube supplied in accordance with
ASTM Standard A269 Type 316L requirements. Seam welded solution annealed A269
Type 316L tube is not acceptable.
5.8.26 If purchase order calls out a specific item pipe length (e.g. 20 ft.), it is meant as a nominal
length for a single random length or a double random length, as applicable.
5.8.29 4" pipe size and smaller fittings, and swages marked as ASTM A234 and/or A105 with the
same Grade/Type markings are acceptable for use on Piping Isometrics. No Piping
Isometric bill of material change is required.
6 Identification
Marking
Requirements
6.1 All materials shall be marked with the information required by the applicable ASTM or
ASME material specification. Marking shall be done by any permanent method that will
neither result in harmful contamination or sharp discontinuities, nor infringe upon the
minimum wall thickness. Any marking material and packing tape used on stainless steel are
required to be made from low chloride (less than 200 ppm) and low sulfur (less than 400
ppm) type material. Fabricator shall provide a chemical analysis report of the marker/tape
for each lot or typical product sample. It is acceptable to use a rounded, low stress, vibro-
etch tool for this marking.
6.2 Pipe, fittings, and flanges shall be color coded if specified in the material requisition.
6.4 Fittings, flanges, and unions are marked in accordance with the applicable ASTM material
specification requirements, including MSS-SP-25, Standard Marking System for Valves,
Fittings, Flanges and Unions. This includes the omission of marking information because of
small fitting, flange or union size or configuration limitations.
This may require special tagging and packaging requirements in order to properly match
and control the small fitting, flange, or union to the Material Certification requirements
listed in Section 8.
8 Certification All carbon steel, stainless steel, steel alloys, and titanium materials shall have a heat
number that is traceable to the Material Test Report (MTR) produced by the material
manufacturer. MTRs shall include, as a minimum, all data required by the applicable
material specification (e.g., chemical analysis, mechanical properties, heat treatment
statement, nondestructive test results, hydrostatic test results, as applicable, and heat
number). A material Certificate of Compliance shall be provided for all other materials.
MTRs or Certificate of Compliance for all materials, as applicable, shall be included with
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 10, Page 10-8
24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
Specification Requirement
the shipment of the materials.
The Material Certificate of Compliance (C of C) shall contain the following information:
a) Buyer purchase order number
b) Buyer purchase order item number
c) Buyer stock code number
d) Manufacturer's name
e) The C of C identifies the specific procurement requirements met by the purchased
material, equipment, or service (i.e. codes, standards, and other specifications)
f) Any approved changes, waivers, or deviations applicable to the material, service, or
equipment (SDDRs).
g) The C of C shall be signed or authenticated by an authorized Supplier
representative.
10 Configuration
Management
Configuration Management is maintained by conformance to approved drawings and
procedures. If approved procedures and drawings cannot be followed, Engineering shall be
promptly notified.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 11, Page 11-1 24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
EXHIBIT 11 | Low Voltage Induction Motors
Specification 24590-WTP-3PS- MUMI-T0002, Rev. 3 was used as applicable to create the following
exhibit. Specification change notices (SCNs) have been evaluated and there are no applicable
SCNs.
Note: All References on this exhibit are inclusive to this exhibit only.
1 Scope
1.2 Equipment,
Material, and Services
Required
1.2.1 This exhibit details the mechanical and electrical requirements for totally enclosed
fan-cooled, and totally enclosed non-ventilated, squirrel-cage induction motors.
1.2.2
All motors covered by this exhibit shall conform to the applicable requirements of
NEMA MG1, ANSI, and NEC standards, except where a deviation is approved by the
Buyer.
1.2.3 Motors manufactured to IEC standards, shall meet the applicable requirements of IEC-
60034 and IEC-60072.
1.2.4
This exhibit is not applicable to the following motors, however, when furnished,
they shall meet the applicable NEMA MG-1 requirements:
a) Special-purpose (non-continuous duty) motors such as those utilized for cranes,
hoists, elevators, motor operated valves, and submersible pumps.
b) Servo-motors
c) Direct current (DC) motors
d) Weather Protected Type I or II (WPI or WPII) motors
1.3 Acceptability
Criteria
1.3.1 All electrical equipment and material shall be suitable for installation and use in
conformity with Article 110-3 of the National Electrical Code, NFPA 70-1999.
1.3.2 Motors of types specifically required by NFPA 70 (e.g. fire water pump, and hazardous
applications) shall be listed.
1.6 Safety/Quality
Classifications
1.6.1
This exhibit covers two general categories of motors based on their quality
classification:
a) Quality level classified as "CM (Commercial Grade - motor meets industry
standards and codes)
b) Deleted.
1.6.2
The Safety Classification, Quality Level and Seismic Category of the motors shall be in
accordance with the system functionality of the referenced primary specification and data
sheets attached to the primary specification.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 11, Page 11-2 24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
2 Applicable
Documents
For the purposes of this exhibit, the word "should" shall be replaced with the word
"shall" wherever it appears in the referenced Codes and Standards.
Any conflicts between the referenced documents shall be identified to the Buyer in
writing for resolution. In general, when resolving conflicts, the following order of
precedence shall apply:
Purchase Order (by the primary specification)
Data Sheets
This Exhibit
Referenced Codes and Standards
Manufacturer Standard
2.2 Industry Standards
IEEE Std. 85 - Test Procedure for Airborne Sound Measurements on Rotating Electric
Machinery
IEEE Std.112 - Test Procedure for Poly-phase Induction Motors and Generators
NEMA MG 1-1998 - Motors and Generators
ABMA 9-1990 - Load Ratings and Fatigue life for Ball Bearings
ABMA 11-1999 - Load Ratings and Fatigue Life for Roller Bearings
IEC-60034 (As applicable) - Rotating Electrical Machines
IEC-60072 (As applicable) - Dimensions and Output Series for Rotating Electrical
Machines
3 Design Requirements
3.1 General
3.1.1 Motors shall be rated for continuous duty for 3-phase, 60 Hz, 460 volts.
3.1.2 All motors shall be NEMA Design B, except in special applications requiring higher
starting torques where other NEMA Design is permitted.
3.2 Environmental
Conditions
The actual environmental conditions requirement of the motors will be shown in the
corresponding primary specification data sheets.
3.3 Electrical
Performance
3.3.1 Voltage Rating
Motors 1/2 Hp to 300 Hp - 460 volts, 3-phase, 60 Hz
Reversing motors - 460 volts, 3-phase, 60 Hz
Note: Deviation from these limits will be permissible if technically justified on a case-
by-case basis.
3.3.2 Insulation System Motors shall be furnished with Class F insulation minimum, and shall be selected for
operation within their full load rating without applying the service factor.
3.3.3 Temperature Rise
Ratings shall be based on a maximum ambient temperature of 40° C, 3,300 feet (1000 m)
altitude or less, with a maximum temperature rise of 80° C by resistance at 1.0 service
factor, (90° C temperature rise at service factor 1.15 up to 150HP). Inverter duty motors
shall not exceed Class F rise at any speed under the defined load.
3.3.4 Locked Rotor
Current
Unless otherwise approved by the Buyer, the locked rotor current of motors shall not
exceed the values as shown in NEMA MG-1-1998, section 12.35.1 "Maximum Locked-
Rotor Current for 60-Hz Design B, C, and D Motors at 230 Volts". The locked-rotor
current of motors designed for voltage 460 shall be proportional to the ratio, 230/460.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 11, Page 11-3 24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
3.3.5 Service Factor The motor shall be sized so that it will not be loaded beyond its design power rating at
service factor of 1.0.
3.3.6 Starting Duty
The motor shall be capable of two successive starts with the motor already at full load
temperature, or three successive motor starts at ambient temperature, accelerating the
load from zero up to full load speed with the motor terminal voltage between 80% and/or
110% of the rated voltage.
3.5 Mechanical
Requirements
3.5.1 General
3.5.1.1 All motors heavier than 50 lbs shall be supplied with an eye bolt for lifting.
3.5.1.2 Where practical, the motor base shall be drilled for ground connection. A bolt
shall be provided complete with nut and washers.
3.5.1.4
Vertical shaft motors for outdoor mounting shall include a steel rain shield,
rigidly mounted to the motor frame, except where the end shield design is such as
to make it unnecessary. The motor end shield shall be so shaped as to prevent
water collecting in the region of the bearing housing.
3.5.1.5 Protection shall be provided against galvanic action between dissimilar metals by
the use of gaskets, washers or other appropriate means.
3.5.1.6 Non-metallic materials shall be fire resistant, anti-static and stable in the presence
of hydrocarbon liquid, vapor and gas.
3.5.2 Motor Enclosures
3.5.2.1 Motor enclosures as required on the data sheets, shall be as follows:
Motors 1/2 hp up to 200 hp: TEFC or TENV (IP54 for IEC motors)
3.5.2.2 Motor enclosures, bearing bracket and fan guard shall preferably be of ferrous material
unless otherwise specified
3.5.3 Drains Where practical, corrosion resistant, replaceable automatic drainage fittings shall be
provided at the low point(s) of the motor enclosure for water drainage.
3.5.4 Mounting The mounting and shaft configuration on all motors shall be defined by the driven
equipment manufacturer.
3.5.5.1
Unless otherwise indicated on the motor data sheets, continuous duty motors shall have
anti-friction type bearings in accordance with the motor manufacturer's standard design.
The bearings shall have basic rating life L-10 of 26,280 h minimum per ABMA 9-1990
or ABMA 11-1999.
3.5.5.3 Vertical motors shall be equipped with thrust bearings and guide bearings.
3.5.6.1 All motors, except those required to be explosion proof, shall have shaft seals
suitable for the environment specified.
3.5.6.2 Shaft seals for continuous duty motors, shall be non-contact-while-rotating type
and shall be used on both motor ends.
3.5.7 Rotor Unless otherwise specified, all motors shall have die cast aluminum rotor cages as
standard.
3.5.8 Bearing
Lubrication
The lubricant and frequency of lubrication of the motors shall be defined by the
manufacturer.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
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Exhibit 11, Page 11-4 24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
3.6 Conduit Boxes
3.6.1 Motor Leads
Conduit Box
a) Conduit boxes shall be rotatable in 90° turns, gasketed, cast iron construction
with tapped conduit entrance hole(s).
b) Deleted.
c) A ground lug shall be provided inside the conduit box on all motors.
d) Conduit box size shall be one size larger than NEMA MG-l/NEC standard.
4 Materials
4.1 Prohibited
Materials
The use of asbestos, PCB and mercury in the manufacture, fabrication, assembly and
finish of
the motors are prohibited.
4.2 Special
Requirements
4.2.1 Design requirements for special motors shall be determined jointly by the Supplier and
the Buyer prior to any fabrication of the motor.
4.3 Nameplates
Each motor shall have a non-corrosive stainless steel nameplate with no less than the
minimum information called for in NEMA MG 1. The nameplates shall be attached with
pins of the same materials, with the following data as a minimum:
1. Manufacturer's Type and Frame designation
2. Horsepower output
3. Time Rating
4. Temperature rise/Insulation Class
5. Speed at rated Load
6. Frequency
7. Number of Phases
8. Rated Voltage
9. Rated Load Current
10. Code Letter for Locked-rotor kVA
11. Service Factor
12. Buyer's Driven Equipment Tag No.
Additional Nameplate Information:
1. Type of Enclosure
2. Manufacturer's name
3. Serial number or date of manufacture
4. Space heater voltage/rating
4.4 Noise Level
4.4.1 Sound level shall be limited to values per NEMA MG-1, Table 9-1.
5 Tests and
Inspections
5.1 Shop Tests
5.1.1
Unless with Buyer's prior written approval, all motors, size and type, shall be subjected
to a "routine test". A complete or "full test'' is required for motors if identified by the
primary specification. All tests shall be performed in accordance with applicable
National
Codes and Industry Standards and/or Manufacturer Standard test procedures and
acceptance. As required, all tests shall be performed at the manufacturer's facility.
Certified test results shall be provided as identified in the primary specification.
5.1.2
The primary equipment Supplier shall maintain all test schedules and upon notification,
the Buyer has the option to witness all the tests to be performed on the motor(s). The
primary equipment Supplier has the ultimate responsibility of all submittals.
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 11, Page 11-5 24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
5.1.3 As a minimum, the following are considered "Routine Test" and "Full Test"
5.1.3.1 Routine Test
a) Measurement of winding resistance (cold).
b) No-load readings of current, power, and nominal speed at rated voltage and
frequency.
c) Mechanical vibration check in accordance with NEMA MG-1, Part 7, using
either elastic or rigid mount.
d) High potential test in accordance with Paragraph 12.3 of NEMA MG-1 Part 12.
5.1.3.2 Full test
(Performance Test)
a) Measurement of winding resistance (cold and hot).
b) No-load readings of current, power, and nominal speed at rated voltage and
frequency.
c) Measurement to allow calculation of locked rotor current and torque.
d) High potential test in accordance with Paragraph 12.3 of NEMA MG-1 Part 12.
e) Inspection (at full load) of bearings and mechanical operation of motor.
f) Full load heat run.
g) Measurement of slip at full load.
h) Measurement to allow calculation of pull-out torque.
i) Measurement to allow calculation of starting torque.
j) Measurement to allow calculation of efficiency at full, three quarter and half
load.
k) Measurement to allow calculation of power factor at full, three quarter and half
load.
l) Mechanical vibration check in accordance with NEMA MG-1, Part 7, using
either elastic or rigid mount.
In cases where one or more of the "full" tests are specified and there are duplicate
motors, only one motor will be subjected for the specified "full" tests.
9 Documentation and
Submittals
9.1 General
9.1.1
For each motor supplied by the driven-equipment manufacturer, the Supplier shall
furnish the following documents as per form G-321E in the primary material requisition:
a) Completed motor data sheets attached to the primary material requisition.
b) Dimensional Outline Drawings for motor including terminal box dimensional
details and arrangement.
c) Wiring diagram
d) Deleted
e) Deleted
f) Installation, operation, and maintenance manual
g) Recommended spare parts list for one year of operation
h) Deleted
i) Assembly drawing, if required
j) Test reports as specified in the primary specification
k) Lubricant Data - Supplier shall identify the manufacturer, grade, viscosity, and
applicable API standard or recommended substitutions. SDS shall be provided
for the lubricant.
l) Data for the gaskets or seals - Supplier to provide the shelf life and cure dates of
gaskets or seals
m) Procedures for long term storage
n) Maintenance procedures
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 12, Page 12-1 24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
EXHIBIT 12 | MINIMUM DESIGN LOADS FOR DEP-VSL-00001
CCN 298617 Rev. N/A was used as applicable to create the following exhibit.
Note: All References on this exhibit are inclusive to this exhibit only.
No zzl e Fo r c es Moments
No zzl e No . S ize
Load Type Fx Fy (lb) (lb) Fz (lb) Mx (f t - lb) My (ft- lb) Mz (ft- lb)
Weight 20 32 20 26 16 16
Seismi c 92 62 92 152 228 228
N2 5 1- 1 / 2 in The rmal 17 15 23 28 55 55
SUM 129 109 135 20 6 299 299
M(i n- l b ) 2 , 466 3 , 5 87 3 , 587
Weight 34 56 34 ~6 29 29
N01, N04 , N11 Seismi c 1 63 108 163 266 398 398
N15, N17 , N2 0 2 in The rmal 30 27 40 ~9 97 97 N2 1 SUM 2 27 191 237 360 524 52~
M(i n- l b ) 4 ,31 6 6 , 280 6 , 280
Weight 71 113 71 180 112 112
N02 , N03 , NOS Seismi c 328 2 18 328 1 , 0 ~7 1 , 567 1 ,567 NOB, Nl O, N12A
3 N18A, N19 , N22
i n The rmal 60 53 80 190 380 3 80
N26 SUM 459 384 478 1, 417 2 , 0 59 2 , 059
M(i n- l b ) 1 6,997 2 4 , 7 04 2 4 , 70 4
Weight 120 192 120 3~2 2H 2H
Seismi c 55 6 372 556 1 , 974 2 , 960 2 , 960
N23 4 i n The rmal 102 9 1 136 360 720 720
SUM 778 654 8 12 2 , 676 3 , 8 9~ 3 , 8 9~
M(i n- l b ) 3 2 , 104 46 , 728 46 , 728
Weight 361 578 361 2 , 2 10 1 , 380 1 , 3 80
Seismi c 1, 694 1 , 127 1,694 12 , 934 19 , 400 19 , 400
N09 , N1 6, N24 10 in The rmal 3 18 284 426 2 , 429 ~ , 8 58 ~ , 858
SUM 2,372 1,988 2 , 48 1 17 , 5 72 25 , 638 25 , 638
M(i n- l b ) 2 10,863 3 07 , 646 307 , 646
Weight 1 , 280 2 , 0 50 1,280 8 , 630 5 , 400 5 , 400
Seismi c 5 , 940 3 , 960 5,940 50 , 600 76 , 000 76 , 000
N13, N14 20 in The rmal 1, 046 932 1,395 8 , 915 17 , 8 29 17 , 829
SUM 8,266 6,942 8 , 615 68 , H S 99 , 229 99 , 229
M(i n- l b ) 8 17 ,732 1 , 190 , 743 1 , 190 , 7 431
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 13, Page 13-1 24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
EXHIBIT 13 | EQUIPMENT NOZZLE LOADS (DEP-VSL-00002)
Note: This exhibit is applicable for Nozzle N07, N10, and N15 only.
Nozzle ID : DEP-VSL-2 N07
LOAD CASE
Weight Weight+Seis Weight+Seis+Therml
NOZZLE FORCE ( LBS ) FX I FY I FZ
2 00 . 1 900 . I
1200 . I
4 10 . I 1100 . 1 2100 . I
2 00 . I 9 00 . I
1 2 00 . I
Nozzle ID : DEP-VSL-2 Nl O
LOAD CASE
Weight Weight+Seis Weight+Seis+Therml
NOZZLE FORCE ( LBS ) FX I FY I FZ
100 . I
2 00 . I 600 . 1
2 00 . I 3 20 . I 4 00 . I
1 00 . I 2 00 . I 6 00 . I
Nozzle ID: DEP-VSL-2_Nl5
LOAD CASE
Weight Weight+Seis Weight+Seis+Therml
NOZZLE FORCE ( LBS ) FX I FY I FZ
70 . I 2 00 . I 3 00 . 1
100 . I 2 00 . I 3 00 . I
70 . I 2 00 . I 3 00 . I
NOZZLE MOMENr (FT- LBS) MX I MY I MZ
10 00 . I 40 00 . I 5 0 00 . I
600 . I 2 000 . I 3 000 . I
1000 . 4000 . 5 000 .
NOZZLE MOMENr (FT- LBS) MX I MY I MZ
2 00 . I
5 00 . I 10 00 . I
200 . I 500 . I
1 000 . I
350 . 1000 . 120 0 .
NOZZLE MOMENr (FT- LBS) MX I MY I MZ
100 . I
5 00 . I 10 00 . I
100 . I 500 . I
1 000 . I
2 70 . 50 0 .
1000 .
24590-BOF-3PS-MVSC-T0002, Rev 3 DFLAW Effluent Management Facility Atmospheric
Process Vessels
Exhibit 14, Page 14-1 24590-G04B-F00019 Rev 4 (2/12/2008) Ref: 24590-WTP-3DP-G04B-00049
EXHIBIT 14 | EQUIPMENT NOZZLE LOADS (DEP-VSL-00003A/B/C)
Note: This exhibit is applicable for Nozzle N05, N08, and N09 only.
Nozzle ID : DEP-VSL-3A/ B/ C_NOS
LOAD CASE
Weight We i ght+Sei:s We i ght+Sei:s+Therm l
NOZZLE FORCE ( LBS) FX I FY I FZ
400 . I
1 600 . I 2600 . 1
800 . I 1100 . 1 1200 . I
360 . I 2 1 00 . I 2 900 . I
Nozzle I D: DEP- VSL- 3A/ B/ C_ N08
LOAD CASE
Weight We i ght+Sei:s We i ght+Sei:s+Therm l
NOZZLE FORCE ( LBS) FX I FY I FZ
30 . I
120 . I 1 50 . I
160 . I 230 . I 2 40 . I
30 . I 80 . I
1 00 . I
Nozzle I D: DEP- VSL- 3A/ B/ C_ N09
LOAD CASE
Weight We i ght+Sei:s We i ght+Sei:s+Therm l
NOZZLE FORCE ( LBS) FX I FY I FZ
30 . I
120 . I 1 50 . I
160 . I 230 . I 2 40 . I
30 . I 80 . I
1 00 . I
NOZZLE MOMENT ( FT- LBS) MX I MY I MZ
1 2 00 . I
3 4 00 . I 6000 . I
5 00 . I 8000 . I
11000 . I
160 0 . 4000 . 5 000 .
NOZZLE MOMENT ( FT- LBS) MX I MY I MZ
40 . I
260 . I 290 . I
4 0 . I 200 . I 220 . I
30 0 . 520 . 550 .
NOZZLE MOMENT ( FT- LBS) MX I MY I MZ
40 . I
260 . I 290 . I
4 0 . I 200 . I 220 . I
30 0 . 520 . 550 .